Upper

Removal
1. Remove the air cleaner.
2. Disconnect the battery ground cable.





3. Remove the water pump pulley shield.
1 Detach the coolant hose from the clip.
2 Remove the bolts.
3 Remove the cover.





4. On SVT equipped vehicles, disconnect the accelerator and speed control cables.
1 Detach the cables from the bracket.
2 Disconnect the accelerator and speed control cables.





5. On SVT equipped vehicles, remove the accelerator cable bracket and disconnect the Exhaust Gas Recirculation (EGR) valve.
1 Remove the accelerator cable bracket nut and bolts.
2 Remove the accelerator cable bracket.
3 Remove the EGR valve bolts and discard the gasket.





6. On non-SVT equipped vehicles, remove the accelerator bracket and the EGR valve from the upper intake manifold.
1 Remove accelerator bracket bolts.
2 Disconnect the accelerator and speed control cables from the throttle body and position to one side.
3 Remove the EGR valve bolts and discard the gasket.





7. Depress the black retainer and disconnect the two vacuum supply hoses from the upper intake manifold.





8. Disconnect the EGR Vacuum Regulator (EVR) vacuum hoses.





9. Disconnect the Position Crankcase Ventilation (PCV) hose and electrical connectors.
- Throttle Position (TP) sensor electrical connector.
- PCV hose.
- Idle Air Control (IAC) valve electrical connector.





10. Disconnect the EVR electrical connector.





11. Remove the bolts in the indicated sequence, remove the upper intake manifold and discard the gaskets.

Installation

NOTE: Make sure the insulating bushings are fitted to the bolts of the upper intake manifold.





1. NOTE: New gaskets must be used, install the gasket on the lower intake manifold.

Install the upper intake manifold and tighten the bolts in the indicated sequence.





2. Connect the EVR electrical connector.





3. Connect the PCV hose and electrical connectors.
- Throttle Position (TP) sensor electrical connector
- PCV hose
- Idle Air Control (IAC) valve electrical connector





4. Connect the EGR Vacuum Regulator (EVR) vacuum hoses.





5. Connect the two vacuum supply hoses to the upper intake manifold.





6. NOTE: Use a new EGR valve gasket.

On non-SVT equipped vehicles, install the accelerator bracket and EGR valve to the upper intake manifold.
1 Install the accelerator bracket and install the bolts.
2 Connect the accelerator and speed control cables to the throttle body.
3 Use the EGR valve and the bolts.





7. NOTE: Use a new EGR gasket.

On SVT equipped vehicles, install the accelerator cable bracket and EGR valve bolts.
1 Install the accelerator cable bracket.
2 Install the accelerator cable bracket nut and bolts.
3 Use a new gasket and install the bolts.





8. On SVT equipped vehicles, connect the accelerator and speed control cables.
1 Connect the accelerator and speed control cables.
2 Attach the cables to the bracket.





9. Install the water pump pulley shield.
1 Install the water pump pulley shield.
2 Install the bolts.
3 Install the coolant expansion tank hose in the clip.
10. Install the air cleaner.

11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

Connect the battery ground cable.