For 1990-2009 cars

## Intake Plenum Switchover Valve Replacement Plenum

#### Tools Required

J 43914 Universal Clamp Pliers

### Removal Procedure

1. Disconnect the negative battery cable.
2. Remove the air cleaner and air inlet hose from the throttle body.
3. Remove the throttle body electrical connector.
4. Remove the electrical connector and vacuum hose from the intake plenum switchover valve solenoid.
5. Remove the vacuum hose from the fuel pressure regulator.
6. Remove the intake plenum hose clamps using the J 43914 and remove the bolts.

Important: It is only necessary to remove the front intake runner to remove the intake plenum.

7. Remove the intake plenum.
8. Remove the plenum mounting bolts and EGR pipe connection.
9. Lift the plenum and remove the throttle body coolant hoses.
10. Remove the throttle body nuts.
11. Remove the throttle body.

### Installation Procedure

1. Install the rear manifold runner, if required. Route the crankcase hoses under the runner.
2. Install the heater hose.
3. Route the crankcase hoses under the runner.
4. Install the coolant hose.
5. Install the throttle body gasket to the plenum.
6. Install the throttle body to the plenum.
7. Install the throttle body nuts.

Tighten
Tighten the throttle body nuts to 8 N·m (71 lb in).

8. Install the intake plenum and intake plenum nuts.
9. Insert the intake plenum bolts.

Tighten
Tighten the intake plenum bolts to 8 N·m (71 lb in).

10. Attach the coolant hoses to the throttle body.
11. Install the EGR pipe connection.

Tighten
Tighten the EGR pipe bolts to 25 N·m (18 lb ft).

12. Install the front manifold runner and tighten the clamps.
13. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolt to 17 N·m (13 lb ft).

14. Install the intake manifold runner bolts.

Tighten
Tighten the intake manifold runner bolts to 8 N·m (71 lb in).

## Intake Plenum Switchover Valve Replacement Runner - Bank 1

#### Tools Required

J 43914 Universal Clamp Pliers

### Removal Procedure

1. Disconnect the negative battery cable.
2. Remove the intake hose assembly. Refer to Air Cleaner and Intake Hose.
3. Remove the ECM electrical connectors.
4. Remove the ECM bolts and ECM.

Important: Clamps are reusable if not damaged. Do not discard.

5. Remove the rubber boot hose clamps using the J 43914 .
6. Disconnect the brake vacuum hose.

Important: Note the proper hose routing.

7. Disconnect the intake plenum switch-over valve vacuum hose at the switch-over valve.
8. Remove the intake runner mounting bolts.
9. Disconnect the intake runner from the rubber boots and remove the intake runner. Note the throttle body vent hose routing under the vacuum reservoir.

### Installation Procedure

1. Install the intake runner onto the rubber boots.
2. Route the throttle body vent hose under the vacuum reservoir.
3. Install the intake runner mounting bolts.

Tighten
Tighten the intake manifold runner bolts to 8 N·m (71 lb in).

4. Route the intake plenum switch-over valve vacuum hose and connect to the switch-over valve.
5. Connect the brake vacuum line.
6. Install the rubber boot hose clamps using the J 43914 .
7. Install the ECM and ECM bolts.

Tighten
Tighten the engine control module bolts to 8 N·m (71 lb in).

8. Install the air cleaner inlet hose assembly. Refer to Air Cleaner and Hose Assembly.
9. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

## Intake Plenum Switchover Valve Replacement Runner - Bank 2

#### Tools Required

J 43914 Universal Clamp Pliers

### Removal Procedure

1. Disconnect the negative battery cable.
2. Remove the air cleaner inlet hose assembly from the throttle body.

Important: Clamps are reusable if not damaged. Do not discard.

3. Remove the rubber boot hose clamps using the J 43914 .
4. Remove the intake runner mounting bolts.
5. Disconnect the intake runner from the rubber boots and remove the intake runner.

### Installation Procedure

1. Install the rubber boots on the intake runner.
2. Install the intake runner mounting bolts.

Tighten
Tighten the intake manifold runner bolts to 8 N·m (71 lb in).

Important: Inspect the hose clamps for damage. Replace if damaged.

3. Install the rubber boot hose clamps using the J 43914 .
4. Install the intake hose assembly.
5. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).