Upper

Removal
1. Disconnect the battery ground cable.
2. Remove the air cleaner assembly and the air cleaner outlet tube.
3. Partially drain the engine coolant system.
4. Relieve the fuel system pressure.
5. Remove the cowl assembly.





6. Position the wire harness aside.
- Remove the retainers.
- Position the wire harness aside.





7. Disconnect the hose.





8. Disconnect the vacuum tube.





9. Disconnect the vacuum tube.





10. Disconnect the hoses.
1Disconnect the coolant hoses.
2 Disconnect the vacuum hose.





11. Disconnect the electrical connectors.
- Disconnect the IDLE AIR CONTROL (IAC).
- Disconnect the Throttle Position (TP) sensor.
- Disconnect the differential pressure feedback sensor.





12. Disconnect the accelerator and speed control cables.





13. Remove the throttle body.
- Remove the bolts.
- Remove the throttle body.





14. Position the differential pressure feedback sensor aside.
- Remove the bolts.
- Position the sensor out of the way.





15. Remove the tube.
- Remove the nuts.
- Remove the tube.





16. Disconnect the vacuum hose.





17. Disconnect the EGR vacuum tube.





18. Disconnect the EGR tube.
- Loosen the nut.





19. Remove the generator bracket.
- Remove the nut.
- Remove the bolt.
- Remove the bracket.





20. Remove the upper intake manifold.
- Remove the bolts.
- Remove the stud bolts.
- Remove the intake manifold.

21. Remove the intake manifold gasket.

Installation
1. Clean all the sealing surfaces.





2. Position a new intake manifold gasket.





3. Position the upper intake manifold.





4. Install the three bolts and the three stud bolts.
- Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten to 20 Nm (14 ft. lbs.).
- Stage 2: Tighten to 25 Nm (18 ft. lbs.).





5. Install the generator bracket.
- Position the bracket.
- Install the bolt.
- Install the nut.





6. Connect the EGR tube.
- Tighten the nut.





7. Connect the vacuum tubes.





8. Connect the vacuum hose.





9. Install the tube.
- Position the tube.
- Install the nuts.





10. Install the differential pressure feedback sensor.
- Position the sensor.
- Install the bolts.





11. Install the throttle body.
- Position a new gasket.
- Position the throttle body.
- Install the bolts.





12. Connect the accelerator and speed control cables.





13. Connect the engine wire harness.
- Connect the throttle position sensor.
- Connect the differential pressure feedback sensor.
- Connect the idle air control (IAC).





14. Connect the hoses.
1 Connect the coolant hoses.
2 Connect the vacuum hose.





15. Connect the vacuum tube.





16. Connect the vacuum tube.





17. Connect the hose.





18. Reposition the wire harness.
- Position the harness.
- Install the retainers.

19. Install the cowl assembly.
20. Refill the engine coolant system.
21. Install the air cleaner assembly and the air cleaner outlet tube.
22. Connect the battery ground cable.