Upper

Removal
1. Disconnect the battery ground cable.
2. Remove the air cleaner assembly and the air cleaner outlet tube.
3. Partially drain the engine coolant system.





4. Disconnect the intake throttle body heater hose.





5. Remove the pin-type retainers and remove the snow shield.





6. Disconnect the accelerator cable, speed control actuator cable and the throttle return spring from the throttle body.





7. Position the accelerator cable bracket aside.
- Remove the bolts.





8. Disconnect the hoses.
- Disconnect the vacuum hose.
- Disconnect the evaporative emissions return tube.





9. Disconnect the electrical connectors.
- Disconnect the Idle Air Control (IAC).
- Disconnect the Throttle Position (TP) sensor.





10. Remove the upper intake manifold support bracket.
- Remove the bolts.
- Remove the nut.





11. Disconnect the Positive Crankcase Ventilation (PCV) tube from the upper intake manifold.





12. Disconnect the Exhaust Gas Recirculation (EGR) tube from the EGR valve.
- Loosen the nut.





13. Disconnect the vacuum tube from the EGR valve.





14. Disconnect the vacuum tube from the upper intake manifold and Electronic Vacuum Regulator (EVR) and disconnect the electrical connector from the EVR.





15. Separate the oxygen sensor connector retainer from the bracket and disconnect the differential pressure feedback EGR vacuum hoses.





16. Disconnect the engine degas hose, differential pressure feedback EGR electrical connector and wire harness retaining clip.





17. Remove the upper intake manifold.
- Remove the six bolts.
- Remove the intake manifold.
18. Remove the intake manifold gasket.

Installation
1. Clean all the scaling surfaces.





2. Position a new intake manifold gasket.





3. Position the upper intake manifold.





4. Install the bolts.
- Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten to 20 Nm (15 ft. lbs.).
- Stage 2: Tighten to 25 Nm (18 ft. lbs.).





5. Connect the engine degas hose, differential pressure feedback EGR electrical connector and position the wire harness retaining clip.





6. Connect the differential pressure feedback EGR vacuum hoses and install the oxygen sensor electrical connector retainer.





7. Connect the electrical connector and vacuum tube to the EVR and the vacuum tube to the intake manifold.





8. Connect the vacuum tube to the EGR valve.





9. Connect the EGR tube to the EGR valve.





10. Connect the PCV tube to the upper intake manifold.





11. Install the upper intake manifold support bracket.





12. Connect the IAC and TP sensor electrical connectors.





13. Connect the evaporative emissions return tube and the vacuum hose.





14. Position the accelerator cable bracket and install the bolts.





15. Connect the accelerator control cable, speed control cable and the throttle return spring.





16. Install the snow shield.





17. Connect the intake throttle body heater hose.
18. Refill the engine coolant system.
19. Install the air cleaner assembly and the air cleaner outlet tube.
20. Connect the battery ground cable.