Catera 2000-2001

Upper Intake Manifold (Plenum)

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake plenum air inlet hoses from the throttle body
     
    Brake booster vacuum hose from the intake plenum
     
    Wiring harness channel from the plenum
     
    Switch over valve electrical connector and vacuum line

    Click image to see an enlarged view

    Fig. Disconnect the accelerator and cruise control cables

     



    Accelerator, cruise control cables and the bracket from the throttle body
     
    Throttle body control electrical connector
     
    Idle Air Control (IAC) inlet hose and electrical connector
     
    Throttle Position Sensor (TPS) electrical connection
     
    Throttle body from the intake plenum
     
    Crankcase vent tube adapter and cover from the intake plenum
     
    Intake plenum and O-rings

    Click image to see an enlarged view

    Fig. Intake plenum mounting bolt locations

     




  4.  

To install:

  1. Install or connect the following:
    NOTE
    Be certain not to strip the threads on the brake booster vacuum hose.



    Intake plenum with new O-rings. Torque the bolts to 71 inch lbs. (8 Nm).
     
    Crankcase vent tube adapter to the intake plenum. Torque the fastener to 71 inch lbs. (8 Nm).
     
    Throttle body to the intake plenum. Torque the fasteners to 106 inch lbs. (12 Nm).
     
    TPS electrical connector
     
    IAC electrical connector and vacuum line
     
    Throttle body control electrical connector
     
    Accelerator and cruise control bracket and cables. Torque the bolts to 71 inch lbs. (8 Nm).
     
    Electrical connector and vacuum hose to the intake plenum switchover valve solenoid
     
    Wiring channel to the intake plenum. Torque the bolts to 71 inch lbs. (8 Nm).
     
    Threaded brake booster vacuum hose to the intake plenum
     



    Intake plenum air inlet hoses to the throttle body
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for proper performance.
  4.  

 
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