Group_09_Intake_Exhaust.pdf

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Intake Manifold Removal and Installation................................................................................................................... 09-2

Exhaust Manifold Removal and Installation ............................................................................................................... 09-8

Exhaust Pipe and Muffler Replacement ..................................................................................................................... 09-9

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Replace if cracked or if mating surface is damaged.

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Replace.

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Replace.

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Replace.

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Replace if cracked or if

mating surface is damaged.

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Remove the throttle cover (A). Fully open the

throttle link and cruise control link by hand, then

remove the throttle cable (B) and cruise control

cable (C) from the links. Loosen the locknuts (D),

and remove the cables from the bracket.

Remove the intake manifold cover.

Disconnect the Intake Air Temperature (IAT) sensor

connector (A), and remove the breather hose (B),

then remove the air cleaner housing (C).

Remove the Evaporative Emission (EVAP) canister

hose (A) and brake booster vacuum hose (B).

(cont’d)

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Remove the water bypass hoses, then plug the

water bypass hoses.

Remove the bolt (A) securing the battery clamp,

then remove the bulkhead cover (B).

Disconnect the Intake Manifold Runner Control

(IMRC) valve actuator control solenoid valve

connector (A), then remove the Positive Crankcase

Ventilation (PCV) hose (B) and IMRC valve control

solenoid valve mounting bolt (C).

Remove the harness clamps.

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Remove the intake air duct mounting bolts (A) and

upper bracket and cushion (B), then remove the

bulkhead (C).

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Install the intake manifold (A) and tighten the bolts/

nuts in a crisscross pattern in two or three steps,

beginning with the inner bolt. Using the new O-

rings (B).

Remove the engine wire harness connectors and

wire harness clamps from the intake manifold.

Idle Air Control (IAC) valve connector

Throttle Position (TP) sensor connector

Manifold Absolute Pressure (MAP) sensor

connector

Install the bulkhead (A), then install the upper

bracket and cushion (B) and intake air duct

mounting bolts (C). Apply body paint to the

bulkhead mounting bolts.

Evaporative Emission (EVAP) canister purge valve

connector

Remove the intake manifold.

(cont’d)

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