Upper

Removal
1. Remove the engine air cleaner outlet tube.





2. Disconnect the following ignition coil electrical connections:
- ignition coil electrical connector (1)
- radio ignition interference capacitor electrical connector (2)
- Idle Air Control (IAC) valve connector (3)





3. CAUTION: The spark plug wires must be connected to the correct ignition coil terminal. Mark the locations before removing the spark plug wires.

Note: Refer to the cylinder-to-coil tower relation indicated.

Disconnect and remove the spark plug wires.





4. Remove the accelerator control splash shield.
1 Remove the bolts.
2 Remove the accelerator control splash shield.





5. Disconnect the (A) accelerator cable end and, if equipped, the (B) speed control actuator cable end.





6. Remove the (A) bolt and, if equipped, the (B) bolt and position the (C) accelerator cable and, if equipped, the (D) speed control actuator cable aside.





7. Disconnect the Evaporative Emissions (EVAP) return tube.





8. Disconnect the brake booster vacuum hose.





9. Disconnect the intake manifold vacuum connection.





10. Disconnect the heated PCV.
- Disconnect the PCV tube.
- Disconnect the water tubes.





11. Remove the Positive Crankcase Ventilation (PCV) valve.





12. Position the EGR bracket aside.
1 Remove the bolts.
2 Position the EGR bracket aside.





13. Disconnect the Throttle Position (TP) sensor electrical connector.





14. Remove the crankcase ventilation hose.





15. Remove the bolts and the upper intake manifold.





16. Remove and discard the intake manifold upper gasket.


Installation





1. Install a new intake manifold upper gasket.





2. Position the upper intake manifold and tighten the upper intake manifold bolts in the sequence shown in three stages.
- Stage 1: Tighten the bolts to 6 Nm (59 inch lbs.).
- Stage 2: Tighten the bolts to 8 Nm (66 inch lbs.)
- Stage 3: Tighten the bolts an additional 90°.






3. Install the crankcase ventilation hose.





4. Connect the Throttle Position (TP) sensor electrical connector.





5. Install the EGR bracket.
1 Position the EGR bracket.
2 Install the stud bolts.





6. Connect the heated PCV.
1 Connect the heater water hoses.
2 Connect the PCV tube.





7. Connect the intake manifold vacuum connection.





8. Install the positive crankcase ventilation valve.





9. Connect the brake booster vacuum hose.





10. Connect the Vapor Management Valve (VMV) hose.





11. Position the (A) accelerator cable and, if equipped, the (B) speed control actuator cable and install the (C) bolt and, if equipped, the (D) bolt.





12. Connect the (A) accelerator cable end and, if equipped, the (B) speed control actuator cable end.





13. Position the (A) accelerator control splash shield and install the (B) bolts.





14. CAUTION: The spark plug wires must be connected to the correct ignition coil terminal. Refer to the location notes made during removal.

Note: Refer to the cylinder-to-coil tower relation indicated.

Install and connect the spark plug wires.





15. Connect the following ignition coil electrical connections.
- ignition coil electrical connector (1)
- radio ignition interference capacitor electrical connector (2)
- Idle Air Control (IAC) valve connector (3)
16. Install the engine air cleaner outlet tube.