Upper Intake Manifold (Plenum)

Upper Intake Manifold:

REMOVAL

1. Disconnect electrical connectors at air bypass valve, throttle position sensor, EGR sensor and air charge temperature sensor (ACT).
2. Remove air inlet tube from air cleaner to throttle body.
3. Remove snow/ice shield to expose throttle linkage. disconnect throttle cable from ball stud.
4. Disconnect upper intake manifold vacuum connectors; both the front and rear fittings including the EGR valve and vacuum line to fuel pressure regulator.
5. Disconnect PCV closure tube from under throttle body and disconnect PCV vacuum tube from under the manifold.
6. Remove canister purge line from fitting near power steering pump.
7. Disconnect EGR tube from EGR valve by removing flange nut.
8. Loosen bolt which retains A/C line at the upper rear of the upper manifold and disengage retainer.
9. Remove six upper intake manifold retaining bolts.
10. Remove upper intake and throttle body as an assembly from lower intake manifold.







INSTALLATION

1. Clean and inspect mounting faces of the lower and upper intake manifold.
2. Position new gasket on lower intake mounting face. The use of alignment studs may be helpful.
3. Install upper intake manifold and throttle body assembly to lower manifold making sure gasket remains in place (if alignment studs aren't used). Align EGR tube in valve.
4. Install six upper intake manifold retaining bolts. Tighten to specification.
5. Engage A/C line retainer cup and tighten bolt to specification.
6. Tighten EGR tube and flare fitting. Tighten lower retainer nut at the exhaust manifold.
7. Install canister purge line to fitting.
8. Connect PCV vacuum hose to bottom of upper manifold and PCV closure hose to throttle body.
9. Connect vacuum lines to vacuum tree, EGR valve, and fuel pressure regulator.
10. Connect throttle cable to throttle body and install snow/ice shield.
11. Connect electrical connector at air bypass valve, TP sensor, EGR sensor, and ACT sensor.

Lower Intake Manifold Torque And Sequence:

NOTE: If lower intake manifold was removed, fill and bleed cooling system.