Repair Procedure B

1. Refer to the 1997-99 3.0CL Service Manual if needed, and remove these components:

^ Throttle body cover (see page 5-4)

^ Intake manifold covers (four total; see pages 5-4 and 6-26)

^ Ignition wire holder (see page 6-26)

^ Ignition wire cover (see page 6-26)

^ Intake air duct (see page 5-3)

^ Brake booster vacuum hose and vacuum hose (see page 5-5)





2. Remove the throttle body from the intake manifold (two nuts and two bolts). Leave all hoses and connections intact as shown. Discard the throttle body gasket(s).

3. Pull the PCV valve out of the cylinder head cover, and remove the intake manifold (three nuts, three washers, and six bolts). Place the manifold on a workbench.





4. Remove and discard the intake manifold chamber. Save the gaskets, brace, intake manifold cover bracket(s), and mounting hardware for reassembly.

5. Disconnect the PCV valve from the PCV hose. Disconnect the PCV hose from the port on the intake manifold. Save one of the hose clamps for reassembly, and discard the hose.





6. Use an 8 mm drill bit and carburetor cleaner to clean the EGR port in the manifold. Turn the drill bit only by hand. Do not use a power drill. After you clean the EGR port, use carburetor cleaner to thoroughly clean the inside of the manifold.

7. Check the EGR port in the front injector base on the engine for blockage. If you see any blockage, clean the EGR port.

8. Install the intake manifold cover bracket(s) you saved in step 4 on the new intake manifold chamber.





9. Slip the new 12 mm diameter hose clamp onto the new PCV hose. Connect the hose to the port on the bottom of the manifold chamber. Secure it with the clamp. Position the clamp with its tangs facing toward the manifold chamber.

10. Install the manifold chamber onto the manifold with the gaskets, brace, and mounting hardware you saved in step 4. Torque the bolts and nuts to 12 Nm (8.7 lb-ft).

11. Connect the other end of the PCV hose to the PCV valve with the hose clamp you saved in step 5.

12. Push the PCV cap onto the intake manifold port. Secure it with the 15.5 mm diameter hose clamp.





13. Reinstall the intake manifold with the original gasket. Be careful not to pinch the PCV hose. Torque the bolts and nuts to 22 Nm (16 lb-ft) sequentially in two or three increments.

14. Push the PCV valve into the cylinder head cover.

15. Reinstall the throttle body on the intake manifold with the new throttle body gasket(s) Torque the nuts and bolts to 22 Nm (16 lb-ft).

16. Reinstall the components removed in step 1.

17. Connect a PGM Tester, with S/N 000 (or higher) software and clear any stored DTCs. Make sure the MIL has gone off and stays off.





18. Center-punch a completion mark above the second character (9) of the engine compartment VIN.