Intake Plenum

REMOVAL

1. Disconnect negative battery cable.
2. Drain coolant.
3. Remove accelerator cable from throttle body.

Throttle Body Air Duct Tube:

4. Remove air duct from throttle body.
5. Mark vacuum and coolant hoses for ease of reassembly. Remove hoses from throttle body.
6. Unplug Throttle Position (TP) sensor, idle switch, and Bypass Air Control (BAC) valve connectors.

Engine Lifting And Coolant Line/EGR Hose Retaining Brackets:

7. Remove engine lifting bracket mounting bolt from throttle body and engine block.
8. Remove coolant line/EGR hose retaining bracket from throttle body.
9. Remove throttle cable retaining brackets from intake plenum.

Vacuum Pipe Mounting Bolt:

10. Remove wire loom bracket and vacuum pipe mounting bolts from intake plenum right side.
11. Remove PCV hose from intake plenum.
12. Remove retaining nuts and bolts from vacuum line assembly bracket at rear of intake plenum.
13. Mark vacuum lines for ease of reassembly and remove lines from intake plenum.
14. Remove plenum retaining nuts and bolts from intake manifold. Remove plenum and gasket.

CAUTION: After plenum removal, cover intake manifold ports with clean cloth to prevent dust and dirt entry.

INSTALLATION

Intake Plenum Installation:

1. Install gasket and position plenum on intake manifold.
2. Install attaching nuts and bolts and tighten to 14 - 19 ft lb (19 - 26 Nm).
3. Install vacuum lines to manifold at correct locations noted during removal.
4. Install retaining bolts and nut on vacuum line assembly bracket to plenum.
5. Install PCV hose to plenum.
6. Install vacuum pipe mounting bolts.
7. Install wire loom bracket mounting bolts to plenum right side.
8. Install throttle cable retaining brackets to front of plenum.
9. Install engine lifting bracket mounting bolt and coolant line/EGR hose retaining bracket to throttle body.
10. Install all vacuum and coolant hoses to throttle body at correct locations noted during removal.
11. Plug in TPS, idle switch, and BAC valve connectors.
12. Install air duct to throttle body.
13. Install accelerator cable to throttle body.
14. Adjust accelerator cable as needed.
15. Refill cooling system.
16. Connect negative battery cable.