Upper

Removal
1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet tube.
3. Disconnect the accelerator cable and the speed control actuator cable.





4. Disconnect the engine control sensor wiring from the Throttle Position (TP) sensor, the Idle Air Control (IAC) valve and the EGR transducer.





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





6. Disconnect the vacuum tube from the EGR valve assembly.





7. Disconnect the EGR solenoid vacuum tube from the upper intake manifold port.





8. Remove the bolt from the 42-pin connector bracket.





9. Remove the throttle body and the throttle body gasket, if necessary.





10. Remove the bolt and the nuts. Position the ignition coil aside.





11. Remove the EGR transducer.
- Remove the bolts.





12. Disconnect the evaporative emission hose.





13. Remove the three bolts and the three stud bolts from the upper intake manifold.





14. Disconnect the crankcase ventilation hose.





15. Remove the upper intake manifold.
16. Remove the intake manifold upper gasket.

Installation
1. Clean all the sealing surfaces.





2. Position a new intake manifold upper gasket.





3. Position the upper intake manifold and align the EGR tube.
- Hand-start the EGR tube-to-EGR nut.





4. Connect the crankcase ventilation hose.





5. Connect the evaporative emission hose.





6. Install the three bolts and the three stud bolts.
- Tighten the bolts in the sequence shown in two steps.
- Tighten to 20 Nm (14 ft. lbs.).
- Tighten to 25 Nm (18 ft. lbs.).





7. Install the EGR transducer.
- Install the bolts.





8. Install the bolt and the nuts.





9. Install the throttle body gasket and throttle body, if removed.





10. Install the bracket.
- Position the bracket.
- Install the bolt.





11. Connect the EGR solenoid vacuum tube.





12. Tighten the EGR tube-to-EGR compression nut.





13. Connect the vacuum tube.





14. Connect the engine control sensor wiring to the throttle position sensor, the idle air control valve and the EGR transducer.





15. Connect the accelerator cable and the speed control actuator cable.
16. Install the air cleaner outlet tube.
17. Connect the battery ground cable.