Non-Turbo

REMOVAL

1. Disconnect the negative battery cable.
2. Drain coolant from radiator.
3. Remove the accelerator cables from the throttle body.
4. Remove the air duct from the throttle body.
5. Remove the hoses from the throttle body.
NOTE: Marking all the vacuum and coolant hoses will make installation easier.
6. Disconnect the throttle position sensor connector, idle switch connector, and bypass air control valve connector.
7. Remove the engine lifting bracket mounting bolts from the throttle body and engine block.
8. Remove the coolant line/EGR hose retaining bracket from the throttle body.
9. Remove the throttle cable retaining brackets from the intake plenum.
10. Remove the wire loom bracket and the EGR back pressure variable transducer bracket from the RH side of the intake plenum.
11. Remove the PCV hose from the intake plenum.
12. Remove the retaining nut and bolts from the vacuum line assembly bracket at the rear of the intake plenum.
13. Remove the lines from the intake plenum.
14. Remove the intake plenum retaining bolts and nuts from the intake manifold.
15. Remove intake plenum and gasket.

INSTALLATION

1. Install gasket and position intake plenum onto the intake manifold.
2. Install attaching bolts and nuts to 14-19 lb. ft. (19-25 N-m).
3. Install all vacuum lines to the intake manifold at their correct location as noted during removal.
4. Install the retaining bolts on the vacuum line assembly bracket to the intake plenum.
5. Install the PCV hose to the intake plenum.
6. Install the wire loom bracket mounting bolts to the RH side of the intake plenum.
7. Install the throttle cable retaining brackets on the front of the intake plenum.
8. Install the engine lifting bracket mounting bolts and coolant line/EGR hose retaining bracket to the throttle body.
9. Install all vacuum and coolant hoses to the throttle body at their correct location as noted during removal.
10. Connect the throttle position sensor connector, idle switch connector, and bypass air control valve connector.
11. Install the air duct to the throttle body.
12. Install the accelerator cables to the throttle body.
13. Refill the cooling system with the proper ratio and level of coolant.
14. Connect the negative battery cable.