Removal

• 1). Open the panel door inside the driver's side of the car and remove the fuel pump relay. This part is labeled, so removal should be straightforward. Start the engine and let it idle until the lack of fuel causes the engine to halt. Open the hood of your car and unbolt the screw that holds the negative connection to the battery, and set aside so that it does not interfere with further maintenance.
  
  
• 2). Place an empty container below the drainage plug of the engine's radiator. Remove the filler cap, located on the upper side of the radiator, and place it aside for later use. Pull the drain plug from the radiator with a pair of pliers and let all of the engine coolant drain completely. Set the coolant container out of the way.
  
  
• 3). Unfasten the brackets that hold the air filter housing unit together and open the housing. Remove the air filter inside to access the housing bolts that connect the piece to the engine. Unscrew these bolts and completely remove the housing unit from the throttle body.
  
  
• 4). Label the electrical wiring and vacuum hoses that attach to the upper intake manifold. It is important that these parts be identified and reattached properly in order to ensure correct engine function. Disconnect these wires and hoses from their respective parts, placing them to the side for later use.
  
  
• 5). Unscrew the bolts that hold the power steering pump in place. Remove this part to allow space for removal of the intake manifold. Remove any remaining parts that block the intake manifold from being removed.
  
  
• 6). Turn the manifold bolts counterclockwise and remove them. Lift the upper intake manifold off the engine and set it aside. Pull the EGR valve injector out of its place. Pry the upper manifold gasket from the engine with a flat head screwdriver.
  
  
• 7). Unbolt the lower intake manifold and remove it completely. Pry the lower manifold gasket off the engine with the flat head screwdriver. Scrape any gunk or build-up from the engine block with a plastic scraper, and wipe any remaining debris with engine degreaser and a linen cloth.
  
  

Installation

• 1). Apply a gasket sealant to the engine block before attaching the new lower gasket. Position the gasket so that the holes align perfectly with the cylinder ports of the engine block. Bolt the lower intake manifold to the block, using the torque wrench to apply 9.5 foot-pounds of pressure.
  
  
• 2). Apply gasket sealant to the upper manifold gasket and position it over the holes of the engine block as well. Bolt the upper intake manifold into position, just as it was removed.
  
  
• 3). Reattach all of the electrical wiring and hoses. Connect any engine parts that were removed at this time.
  
  
• 4). Reconnect the air filter housing unit and attach the air filter. Pour the engine coolant back into the radiator and replace the filler cap when you are finished.
  
  
• 5). Reconnect the fuel pump relay to its dock in the panel door. Reconnect the negative battery cable.