Intake Air Plenum: Service and Repair

Before starting, disconnect battery ground cable and drain coolant.

Intake Manifold Removal:

1. Disconnect accelerator cable.
2. Disconnect ventilation hose from air duct.
3. Disconnect air hose from air duct.
4. Remove air duct.
5. Disconnect EGR valve vacuum hose from EGR valve.
6. Disconnect fuel feed hose from intake manifold.
7. Disconnect EGR water temperature sensor.
8. Remove water hoses.
9. Disconnect vacuum hoses from thermal valve.
10. Remove pressure regulator bracket.
11. Remove EGR pipe flange nut.
12. Remove air regulator connector.
13. Remove air regulator hose.
14. Remove EGR pressure regulator hose.
15. Remove throttle body bolts.
16. Remove common chamber bolts and nuts but do not remove throttle body from cylinder head.
17. Remove common chamber.
18. Reverse steps to refit, noting the following torque specs:

Common chamber fasteners
20 ft lb (27 Nm)
EGR pipe flange nut
33 ft lb (44 Nm)