Upper Intake Manifold

Fuel Charging Assembly:

REMOVAL
1. Disconnect electrical connectors at:
a. EVP sensor.
b. Throttle position sensor.
c. Air bypass valve.

Fuel Charging Assembly:

2. Disconnect the following vacuum connections:
a. Vacuum line at the EGR valve.
b. Sealed Housing Evaporative Determination System (S.H.E.D.) evap lines to the throttle body.
c. Vacuum lines to the upper intake manifold vacuum tree. Leveling the hose locations with tape is recommended to aid installation.
3. Disconnect the PCV hose from the fittings located on the underside of the upper intake manifold.

Throttle Body Assembly:

4. Remove the throttle linkage shield, and disconnect the throttle linkage and speed control cables. Unbolt the accelerator cable from the bracket and position the cable away from the engine.

CAUTION: When disconnecting throttle cable from ball stud, use a screwdriver or similar tool close to the ball stud to pry off. Removing by hand may damage the cable.

5. Disconnect the air inlet hoses from the throttle body.

Fuel Charging Assembly:

6. Disconnect the EGR tube from the EGR valve and the rear exhaust manifold. Remove the tube from the engine.
7. Remove the thermactor tube assembly from the lower intake manifold by removing the two nuts retaining the tube. Remove the nut attaching the thermactor bypass valve bracket to the lower intake manifold stud.

Fuel Charging Assembly:

8. Remove the seven studs that retain the upper intake manifold.
9. Remove the screw and washer assembly attaching the upper intake manifold support bracket to the upper intake manifold.
10. Remove the upper intake manifold and throttle body assembly from the lower intake manifold.

INSTALLATION
1. Position a new upper intake gasket on the lower manifold, using the lower manifold dowels to position the gasket.
2. Position the upper intake manifold onto the lower intake manifold, using the dowels of the lower intake to locate manifold holes. Install the seven studs to attach the upper intake to the lower intake manifold, hand-tighten.
3. Tighten the seven studs, attaching the upper intake to the lower intake manifold to 16-24 Nm (12-18 ft lb).
4. Position the upper intake manifold support onto the base of the upper intake, located under the throttle body. Install the retaining bolt.
5. Install the EGR tube between the EGR valve and the rear exhaust manifold. The tube is routed between lower intake runners No. 4 and No. 5. Tighten both fittings to 33.8-47.5 Nm (25-35 ft lb).
6. Connect the PCV hose to the fitting, located on the underside of the upper intake manifold.
7. Position the thermactor tube assembly onto the studs of the lower intake manifold.
8. Install the accelerator cable and throttle linkage shield onto the accelerator bracket of the throttle body.
9. Connect the air inlet hoses to the throttle body.
10. Connect the following vacuum connections:
a. Vacuum line to the EGR valve.
b. Evap lines to the throttle body.
c. Vacuum lines to the upper intake manifold vacuum tree.
11. Connect the following electrical connectors at:
a. Throttle position sensor.
b. Air bypass valve.
c. EVP sensor.