Removal

Intake Manifold

Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running.

All vehicles
1. Disconnect the battery ground cable.
2. Relieve the fuel system pressure.
3. Drain the cooling system.





4. Disconnect the idle air control (IAC) fresh air tube and crankcase ventilation tube from the air cleaner outlet pipe.





5. Loosen the clamp and disconnect the air cleaner outlet pipe from the throttle body.





6. Release the clamp and separate the air cleaner outlet housing from the air cleaner inlet housing.





7. Disconnect the mass air flow (MAF) sensor electrical connector and remove the air cleaner, air cleaner outlet housing and the air cleaner outlet pipe from the vehicle.





8. Compress and slide the hose clamp and disconnect the upper radiator hose.

Vehicles with A/C





9. Rotate the belt tensioner clockwise and remove the belt from the generator pulley.

Vehicles without A/C





10. Rotate the belt tensioner counterclockwise and remove the belt from the generator pulley.

All vehicles





11. Remove the harness routing clips from the generator stud and the engine front cover.





12. Remove the generator upper mounting bracket stud and bolt.





13. Remove the generator lower mounting bolts and position the generator aside.





14. Remove the accelerator control splash shield.





15. Disconnect the throttle body cam.
^ Disconnect the accelerator cable.
^ If equipped, disconnect the speed control cable.
^ Remove the throttle return spring.





16. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the accelerator cable bracket aside.





17. Disconnect the throttle position (TP) sensor electrical connector.





18. Release the IAC fresh air tube from the routing clip and remove it from the vehicle.





19. Disconnect the evaporative emission canister purge valve vacuum hose from the throttle body adapter.





20. Disconnect the brake booster vacuum hose and main vacuum harness from the throttle body adapter.





21. Disconnect the IAC electrical connector.

Vehicles with EGR system





22. Position the exhaust manifold to EGR valve tube aside.
^ Disconnect the upper fitting.
^ Loosen the lower fitting.
^ Position the exhaust manifold to EGR valve tube aside.





23. Position the differential pressure feedback exhaust gas recirculation (EGR) system bracket aside.
^ Remove the bolts.
^ Position the bracket aside.





24. Disconnect the EGR vacuum regulator solenoid connections.





25. Disconnect the EGR valve vacuum hose.

All vehicles








26. Remove the throttle body adapter.
^ Remove the four bolts.
^ Remove the throttle body adapter.
^ Remove and discard the throttle body gasket.
27. Disconnect the fuel lines.





28. Disconnect the positive crankcase ventilation (PCV) valve tube from the intake manifold.





29. Disconnect the fuel pressure regulator vacuum hose.





30. Disconnect the eight ignition coil electrical connectors and remove the coils.





31. Disconnect the eight fuel injector electrical connectors.





32. Disconnect the hose clamp and remove the heater water hose.





33. Remove the bolts, water thermostat housing, O-ring seal and the water thermostat.
^ Discard the O-ring seal.





34. Remove the bolts.





35. Remove the intake manifold.
^ Lift the intake manifold.
^ Remove and discard the intake manifold gaskets.

36. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths.

Clean all mating surfaces.