Removal and Installation

Removal - V6 models only

  1. It is probably easiest to go ahead and remove the distributor cap (2 phillips screws) and rotor now. Just pull the coil wire off of the coil, and the wires should reach far enough that you can set the cap over near the thermostat housing, without disconnecting any of the plug wires, and they will all be out of the way.
  2. Remove the 2 nuts that hold the EGR tube to the EGR valve adapter.
  3. If you need to remove the throttle body so it will be out of the way, either remove the coolant lines that run to it at the throttle body (mine were stuck and I could not remove them there), or wait until after you have removed the plenum and remove the hoses from the other end. The throttle body will stay where it is without anything else holding it up.
  4. Remove the 2 Torx T-40 bolts that hold the throttle body to the plenum.
  5. Remove the 12-point 8mm bolt that holds the throttle body coolant tubes to the plenum.
  6. Remove the 2 12-point 10mm bolts that hold the throttle (and cruise control, if equipped) cables in place.
  7. Remove the 10 12-point 10mm bolts that hold the plenum to the middle intake manifold. I keep mine in the same order by setting them in the slots on one of the louvered engine compartment side covers.
  8. Pull all of the vacuum tubes off of the plenum. There is one underneath towards the throttle body end which you probably can not get off until everything else is off and the plenum is lifted.
  9. After you remove the plenum, you can remove the EGR tube (two 10mm bolts) if necessary.

From: Sketch


If you have the time, just a few hours, you can remove the air plenum and refinish it. I had to take it off to fix the EGR tube. I used rough sand paper to remove all the corrosion, then smoothened it with fine paper. I repainted it with high temp paint and put a nice shiny clear coat on it. So pretty after I put it back on, I wouldn't want to hide it with a shade. By the way, if anyone out there has ever had a problem with this tube breaking at the flange, instead of spending close to $100 to replace it, I would first bring it to someone who can weld it back for you. I paid someone $10 to do it.

From: Henry W.T. Luk

[Top] | Online Service Guide Main Page