Lower

Intake Manifold-Upper

Removal
1. Remove the Air Cleaner (ACL).
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. Remove the accelerator bracket and the Exhaust Gas Recirculation (EGR) valve from the upper intake manifold.
1. Remove the bolts.
2. Disconnect accelerator and speed control cables from the throttle body and position to one side.
3. Remove the bolts and discard the gasket.





5. Depress the retainer and disconnect the two vacuum supply lines from the upper intake.





6. Disconnect the EGR vacuum regulator hoses.





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





8. Disconnect the EGR vacuum regulator solenoid electrical connector.

9. NOTE: Remove the bolts in the indicated sequence.





Remove the upper intake manifold and discard the gaskets.

Installation





1. NOTE:
^ Verify the insulating bushings are on the bolts of the upper intake manifold.
^ New gaskets must be used, position the gasket on the lower intake manifold.
^ Tighten the bolts in the indicated sequence.

Position the upper intake manifold and tighten the bolts.





2. Connect the EGR vacuum regulator solenoid electrical connector.





3. Connect the PCV hose and electrical connectors.
^ TP sensor electrical connector.
^ PCV hose.
^ IAC valve electrical connector.





4. Connect the EGR vacuum regulator hoses.





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





6. NOTE: Use a new EGR valve gasket.

Install the accelerator bracket and EGR valve to the upper intake manifold.
1. Position the accelerator bracket and install the bolts.
2. Connect the accelerator and speed control cables to the throttle body.
3. Position the EGR valve and the bolts.





7. Install the water pump pulley cover.
1. Install the cover.
2. Install the bolts.
3. Attach the coolant hose to the clip.
8. Install the ACL.

9. 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 battery ground cable.