Upper Intake Manifold

Upper Intake Manifold

Removal
1. Partially drain the cooling system.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.





4. Remove the accelerator control splash shield.





5. Disconnect the accelerator cable, the speed control cable and the return spring.





6. Disconnect the fuel vapor hose.





7. Remove the accelerator control cable from the bracket.





8. Remove the speed control cable from the bracket.





9. Disconnect the vacuum hose.





10. Remove the bolt, disconnect the acceleration control cables and position them aside.





11. Remove the bolt and the bracket.





12. Disconnect the Exhaust Gas Recirculation (EGR) system module tube from the EGR system module.





13. Disconnect the Throttle Position (TP) sensor and the Idle Air Control (IAC) sensor electrical connectors.





14. Disconnect the Positive Crankcase Ventilation (PVC) tube.





15. Disconnect the EGR system module electrical connector.





16. Disconnect the vacuum hoses and the Positive Crankcase Ventilation (PCV) coolant hoses.





17. Remove the upper intake manifold assembly bolts in the sequence shown. Remove the intake manifold assembly.





18. Inspect and clean the sealing surfaces.

Installation





1. Install a new upper intake manifold gasket.





2. Install the upper intake manifold and bolts in the sequence shown.





3. Connect the vacuum hoses and the PCV coolant hoses.





4. Connect the EGR system module electrical connector.





5. Connect the Positive Crankcase Ventilation (PVC) tube.





6. Connect the Throttle Position (TP) sensor and the Idle Air Control (IAC) sensor electrical connectors.





7. Connect the Exhaust Gas Recirculation (EGR) system module tube from the EGR system module.





8. Install the bracket and the bolt.





9. Install the bolt, and connect the acceleration control cables.





10. Connect the vacuum hose.





11. Install the accelerator control cables.





12. Connect the fuel vapor hose.





13. Connect the accelerator cable, the speed control cable and the return spring.





14. Install the accelerator control splash shield.
15. Install the air cleaner outlet tube.
16. Connect the battery ground cable.
17. Partially fill and bleed the cooling system.