Upper Intake Manifold

Removal

1. Remove the air cleaner outlet tube.
   1. Remove the crankcase ventilation tube.
   2. Loosen the clamps.
   3. Remove the air cleaner outlet tube.

2. Remove the three nuts and the engine appearance cover.

3. Disconnect the cables.
   1. Disconnect the throttle cable.
   2. If equipped, disconnect the speed control cable.
   3. Remove the throttle cable bracket bolts.

4. Disconnect the throttle position (TP) sensor and idle air control (IAC) electrical connectors.

5. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose and EGR tube nut.

6. Disconnect the EGR vacuum regulator solenoid electrical connector and vacuum hose.

7. Disconnect the three vacuum hoses on the back of the intake manifold.
   1. Disconnect the chassis vacuum hose.
   2. Disconnect the engine vacuum hose.
   3. Disconnect the positive crankcase ventilation (PCV) hose.

8. Disconnect the vapor management valve (VMV) vacuum hose.

9. Disconnect the two electrical connectors attached to the left side of the upper intake manifold.

10. Disconnect the power steering pressure (PSP) sensor electrical connector.

11. Remove the bolt and position the transmission vent hose and bracket aside.

12. Remove the nut from the wire harness.

13. Remove the eight bolts and the upper intake manifold.
    • Remove and discard the gaskets.
    • Clean all sealing surfaces.

Installation

1. Install new gaskets in the upper intake manifold.

2. Position the upper intake manifold and tighten the bolts in the sequence shown.

3. Connect the PSP electrical connector.

4. Position the transmission vent tube and bracket and install the bolt.

5. Position the wire harness and install the nut.

6. Install the two electrical connectors on the left side of the intake manifold.

7. Install the vapor management valve (VMV) vacuum hose.

8. Connect the three vacuum hoses on the back of the upper intake manifold.
   1. Connect the chassis vacuum hose.
   2. Connect the engine vacuum hose.
   3. Connect the PCV hose.

9. Connect the EGR vacuum regulator solenoid electrical connector and the vacuum hose.

10. Install the EGR valve vacuum hose and EGR tube nut.

11. Connect the TP sensor and IAC electrical connectors.

12. Connect the throttle cables.
    1. Install the throttle cable bracket bolts.
    2. Connect the throttle cable.
    3. If equipped, connect the speed control cable.

13. Install the air cleaner outlet tube.
    1. Position the air cleaner outlet tube.
    2. Install the hoses.
    3. Install the clamps.

14. Install the engine appearance cover.