Removal

1. Disconnect the battery ground cable.
2. Drain the engine cooling system.
3. Remove the air cleaner outlet tube.
4. Disconnect the fuel line.





5. Remove the two nuts retaining the engine sensor control wiring to the valve covers.





6. Remove the nut and the bolt and position the generator battery lead out of the way.





7. Disconnect the generator electrical connector.





8. Remove the generator mounting bracket.
^ Remove the bolts and nuts.
^ Remove the bracket.





9. Disconnect the coolant hoses from the water bypass tube.





10. Remove the nuts and remove the bypass tube.





11. Separate the mass air flow sensor connector from the accelerator snow shield and disconnect.





12. Remove the bolt and the pushpin and remove the snow shield.





13. Disconnect the accelerator cable and the speed control actuator cable from the throttle body.





14. Remove the bolts and the accelerator cable bracket, position it out of the way.





15. Disconnect the chassis vacuum supply tube, the positive crankcase ventilation tube and the engine vacuum supply line.





16. Disconnect the fuel pressure sensor vacuum line and the electrical connector.





17. Disconnect the evaporative emissions return line.





18. Disconnect the heater water hose.





19. Disconnect the vacuum lines from the EGR Vacuum Regulator (EVR) solenoid.





20. Disconnect the vacuum line from the Exhaust Gas Recirculation (EGR) valve.





21. Disconnect the electrical connectors from the eight fuel injectors.





22. Disconnect the engine control sensor wiring electrical connectors from:
^ The Idle Air Control (IAC) valve.
^ the Throttle Position (TP) sensor.
^ the Mass Airflow (MAF) sensor.





23. Disconnect the EGR tube at the EGR valve. Disconnect the four LH ignition coils.
25. Disconnect the starter electrical connectors.





26. Position the fuel charging wiring aside.





27. Loosen and remove the bolts and the studs in sequence, in three stages and remove the intake manifold assembly.
28. Remove the intake manifold gaskets and discard.





29. Remove the EGR valve.
^ Remove the bolts.
^ Remove the EGR valve.





30. Remove the idle air control valve.
^ Remove the bolts.
^ Remove the idle air control valve.





31. Remove the throttle body.
^ Remove the bolts.
^ Remove the throttle body.
^ Replace the gasket.





32. Clean all the sealing surfaces.