Turbo

REMOVAL

Intake Air Duct:

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.

Throttle Body:

5. Mark all vacuum and coolant hoses for ease of reassembly and remove the hoses from the throttle body and engine block.
6. Disconnect the Throttle Position Sensor connector, Idle Switch connector, and the Bypass Air Control Valve connector.

Engine Lifting Bracket:

7. Remove the engine lifting bracket mounting bolt from the throttle body.
8. Remove the coolant line/EGR hose retaining bracket from the throttle body.

Throttle Cable Retaining Brackets:

9. Remove the throttle cable retaining brackets from the intake plenum.
10. Remove the wire loom bracket and the vacuum pipe mounting bolts from the RH side of the intake plenum.

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. Mark all vacuum lines for ease of reassembly and 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.
CAUTION: After removing the intake plenum, cover the intake manifold ports with a clean cloth to prevent dust and dirt from entering.

INSTALLATION

1. Install a new gasket and position intake plenum onto the intake manifold.
2. Install the attaching bolts and nuts and tighten 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 bots 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 bolt 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.