Upper Intake Manifold

Removal
1. Disconnect the negative battery cable.
2. Partially drain the cooling system.




3. Remove the air cleaner outlet tube.
4. Remove the two bolts and the snow shield.




5. Disconnect the accelerator cable and the cruise control actuator cable.




6. Disconnect the engine control sensor wiring from the throttle position (TP) sensor, the idle air control (IAC) valve and the EGR transducer.




7. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.
1. Loosen the compression nut.




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




9. Disconnect the EGR solenoid vacuum tube and the brake booster vacuum hose from the upper intake manifold port.




10. Loosen the bolt and position the 42-pin wiring harness out of the way.




11. Remove the 42-pin connect from the bracket and position out of the way.




12. Mark and disconnect the EGR transducer hoses.




13. Disconnect the evaporative emission hose.




14. Disconnect the heater water hoses at the intake manifold.




15. Remove the positive crankcase ventilation (PCV) valve from the valve cover.




16. Loosen the bottom nut and remove the bolt. Position the intake manifold support bracket out of the way.




17. Remove the bolt and position the exhaust gas re-circulation (EGR) vacuum regulator valve out of the way.
18. Remove the upper intake manifold.
19. 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 install the five bolts hand tight.




4. Position back the exhaust gas recirculation (EGR) vacuum regulator valve and install the bolt hand tight.




5. Tighten the intake manifold bolts in two steps and in the sequence shown.
1. Tighten to 10 N.m (89 lb-in).
2. Tighten to 20 N.m (15 lb-ft).




6. Position back the intake manifold support bracket and install the bolt. Tighten the bottom nut.




7. Install the positive crankcase ventilation (PCV) valve into the valve cover.




8. Connect the evaporative emission hose.




9. Connect the heater water hoses at the intake manifold.




10. Connect the EGR transducer hoses.




11. Install the engine wiring harness on the bracket.




12. Connect the 42-pin wiring harness and tighten the bolt.




13. Connect the EGR solenoid vacuum tube and the brake booster vacuum hose.




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




15. Connect the vacuum tube.




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




17. Connect the accelerator cable and the cruise control actuator cable.
18. Install the snow shield and the two bolts.
19. Install the air cleaner outlet tube.
20. Fill the cooling system.
21. Connect the negative battery cable.