Removal - Upper Intake Manifold (Plenum)

We decided that we wanted to have the Upper Intake Manifold (also referred to as the plenum) painted, so the first step was removal of the plenum. There are lots of parts to remove, although not a difficult job. The sequence of removal of the items identified below is only a suggestion.

*

Disconnect negative (and positive) cable from battery
1

Remove front engine compartment supports

(bolts - 2 x 10mm, 2 x 13mm)
2

Remove upper radiator crossmember

(bolts - 4 x 13mm; nuts - 2 x 10mm)
3

Remove air cleaner intake duct
4

Remove throttle and speed control cables from the throttle arm and bracket

(note: it was easier to remove the bracket from the plenum first, in order to relieve the tension on the cables)
(bolts - 2 x 8mm)
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Disconnect electrical connectors from the following sensors:
5

Manifold Tuning Valve (MTV)

(note: we found that it was easier to disconnect this harness at the very end, while lifting plenum - after all other items were disconnected, and bolts/nuts removed)
6

Intake Air Temperature/Manifold Absolute Pressure (TMAP)

(bolts - 2 x T-20)
7

Throttle Position Sensor (TPS)
8
Idle Air Cntrol (IAC)
*

Disconnect vacuum hoses from the following:
9

Proportional purge solenoid
10

Speed Control Reservior
11

Brake Booster
12

Positive Crankcase Ventilation (PCV) Valve
13

Secondary Runner Valve (SRV) Solenoid

(note: this remains attached to the plenum until after plenum has been removed from the engine bay. One end attaches to the diaphram on the underside of plenum and is very difficult to reach while still in the engine bay)
14

Remove left side (Intake Manifold Support-Left Side) intake manifold support

(note: you don't need to remove lower bolts unless you intend to paint this support)
(upper bolt - 1 x 13mm; lower bolts - 2 x 8mm, 2 x 15mm)
15

Remove right side (Intake Manifold Support-Right Side) intake manifold support

(note: you don't need to remove lower bolt unless you intend to paint this support)
(upper bolt - 1 x 13mm; lower bolt - 1 x 15mm)
16

Remove support brackets at intake manifold front corners and at MTV (Intake Manifold Supports-Front)

(upper bolts - left & right 2 x 10mm, middle - nut 1 x 10mm; lower bolts - 3 x 13mm)
17

Remove clips attaching EGR tubes to intake manifold

(note: these are tricky to remove, you have to pull them towards the firewall)
(2 spring retaining clips)
18

Remove bolts attaching intake manifold and remove manifold (Upper Intake Manifold)

(bolts - 7 x 10mm)
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After removing the plenum, we removed the diaphram and throttle body since they weren't going to be painted
*

Remove Diaphram

(bolts - 2 x T-25; nut - 1 x 8mm)
*

Remove Throttle body

(note: the throttle body is upside down in this picture)
(bolts - 1 x T-25, 2 x T-30)
*

There is a neo-prene gasket on the bottom of the plenum, and also between the plenum and the throttle body.
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We used a heat gun and small thin screwdriver to remove the 3.5 liter emblem on the plenum.

Parts ready for the paint shop

 

Click here to see the results of the painting
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