Valve Cover: Service and Repair

Injection Sound Insulation:

1. Disconnect the battery ground strap under the right rear seat.
2. Remove the four plugs from the sound insulation cover and disconnect the cover.

Coolant Expansion Tank Removal:

3. Disconnect the coolant level sender electrical plug.
4. Remove the spill hose.
5. Remove the nuts on both sides of the expansion tank and remove the expansion tank.

NOTE: Do not disconnect the coolant hoses from the expansion tank.

Electrical Connector Location:

6. Pull connectors 1 - 4 off

Electrical Connector Locations:

7. Remove the electrical connectors from the fuel injectors.
8. Remove the electrical connectors from the throttle valve motors.

Fuel Rail Connections:

9. Disconnect the fuel return connectors.
10. Disconnect the fuel return and fuel supply lines.
11. Remove the vacuum lines from the fuel pressure regulators.
12. Remove the fuel rail mounting screws and lift out the fuel rail along with the fuel injectors.

Throttle Neck View:

13. Loosen the large clamps at the intake air boots and remove the intake air boots.
14. Remove the distributor caps.
15. Remove the retaining bolts at the throttle valve motors and remove the throttle valves.
16. Drain the fluid from the windshield washing reservoir.
17. Remove the pumps and the level sender from the windshield washing reservoir.
18. Remove the reservoir.
19. Disconnect the ignition wire conduit from the intake manifold.

Inlet Air Temperature Sensor Location:

20. Disconnect the intake air temperature sensor electrical connector.

Fastener Locations:

21. Loosen the nuts of the manifold support several turns.

Noise Suppressor Location:

22. Unscrew the noise suppressor.

Intake Manifold Bolt Location:

23. Remove the intake manifold mounting nuts with special tool (11 6 060) and lift off the intake manifold.
24. Replace in the reverse manner.

NOTE: Intake manifold mounting nut torque = 7 ft. lbs. (10 Nm).