Intake Air Plenum: Service and Repair

Fig. 5 Common chamber replacement.:

Turbo Engine

Refer to Fig. 5, during removal and installation of the common chamber.
1. Remove intercooler from throttle valve assembly.
2. Remove air cleaner duct with air cleaner upper case.
3. Remove backpressure transducer bracket, then the VSV assembly with vacuum line assembly.
4. Remove intercooler rear bracket, then the breather hoses.
5. Disconnect PCV hose, then the MAP sensor hose.
6. Disconnect vacuum booster hose from throttle valve assembly.
7. Disconnect canister hoses, then the EGR vacuum lines.
8. Disconnect heater hose to bypass line from throttle valve assembly.
9. Remove throttle valve assembly from common chamber.
10. Disconnect alternator harness clip, then remove four short chamber retaining bolts, two long bolts and two nuts.
11. Remove common chamber from engine assembly.
12. Reverse procedure to install, noting the following:
a. Ensure sealing surfaces of both the common chamber and induction control assembly are completely free of old gasket material.
b. Torque EGR pipe to EGR valve to 32 ft. lbs.
c. Torque common chamber retaining nuts and bolts to 17 ft. lbs.

Fig. 6 Common chamber replacement:

Non Turbo Engine

Refer to Fig. 6, during removal and installation of the common chamber.
1. Disconnect ground cable terminals from common chamber.
2. Mark vacuum lines for installation, then disconnect vacuum lines from common chamber.
3. Remove throttle valve assembly from common chamber.
4. Disconnect EGR valve, then remove EGR and bracket.
5. Remove alternator harness retaining clip.
6. Remove common chamber retaining bolts and nuts, then chamber assembly.
7. Reverse procedure to install, noting the following:
a. Ensure sealing surfaces of both the common chamber and induction control assembly are completely free of old gasket material.