Intake Manifold - Removal

REMOVAL





1. Perform the fuel pressure release procedure Service and Repair.
2. Recover the refrigerant from the refrigerant system Refrigerant System Recovery.
3. Remove the engine cover (1).





4. Remove the air cleaner body (6) Air Cleaner Body - Removal.





5. Disconnect the PCV hose (1) from the intake manifold.
6. Disconnect the vent hose (3) from the oil filler neck.
7. Remove three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.





8. Disconnect the fuel vapor purge hose (3) from the intake manifold.
9. Open the hose retainer (1) and disconnect the fuel line (2) from the fuel rail Service and Repair.






CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

10. Disconnect and remove the battery Battery - Removal.
11. Unlock and disconnect the Powertrain Control Module (PCM) harness connectors (1 and 2).





12. Disengage two starter wire harness retainers (6) from the battery tray (3).
13. Disengage two engine wire harness retainers (4) from the battery tray (3).
14. Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
15. Remove the nut (5) and two bolts (1).





16. Open the two wire harness retainers (3) and reposition the wire harness.
17. Remove the nut (1) and the ground strap (4).
18. Remove the battery tray with the PCM (2) attached.





19. Unlock and disconnect the IAT/MAP sensor harness connector (1).





20. Unlock and disconnect the evaporative emissions purge solenoid harness connector (1).
21. Unlock and disconnect the fuel injector harness connector (2).





22. Unlock and disconnect the harness connector (3) from the Electronic Throttle Control (ETC) (4) and disengage the ETC harness from the clip (2) on the throttle body.





23. Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1).





24. Disconnect the vacuum line from the vacuum pump (1).





25. Raise and support the vehicle Maintenance.
26. Remove the belly pan Belly Pan - Removal.
27. Drain the cooling system Service and Repair.





28. Remove four bolts (1) and the tunnel support brace (2). Reinstall the four bolts (1) to maintain alignment of the frame extensions. Tighten the bolts (1) to 90 Nm (60 ft. lb.).





29. If equipped with a manual transmission, remove the rear engine mount bracket bolt (3) and nut (6), loosen the isolator bolt (1) and reposition the rear engine mount isolator (7) away from the bracket (5).





30. If equipped with an automatic transmission, remove two bolts (4) from the rear engine mount bracket (3), loosen the bolt (1) and reposition the rear engine mount link (5) away from the bracket (3).





31. Remove the engine cooling fan (2) Cooling Fan - Removal.





32. Remove two bolts (4) and the right vertical brace (5).
33. Remove two screws (2) from the front wheelhouse splash shield.
34. Remove three screws (1) and the frame splash shield (3).





35. Remove the accessory drive belt (4) Serpentine Accessory Drive Belt - Removal.





36. Remove the A/C compressor (1) A/C Compressor - Removal.





37. Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.





38. Open the two wire harness retainers (1) and reposition the wire harness.





39. Remove six of the seven intake manifold flange bolts (1).





40. Disconnect the lower coolant hose from the radiator.
41. Reposition the coolant recovery bottle (5) Coolant Recovery Bottle - Removal.





42. Support the engine with a floor jack positioned under the oil pan.
43. Remove six bolts (1 and 3) and the RH engine mount isolator (4).





44. Slowly lower the engine so that it rolls forward and down.
45. Remove the remaining intake manifold flange bolt (3), the intake manifold support bolt (2) and remove the intake manifold (1) from the vehicle through the space normally occupied by the battery.





46. Remove and discard the four intake manifold seals (1).
47. Cover the open intake ports to prevent debris from entering the engine.
48. If required, remove the following components from the intake manifold:
- Throttle body Throttle Body - Removal.
- Fuel rail Fuel Rail - Removal.
- Fuel injector(s) Fuel Injector - Removal.
- Evaporative emissions purge solenoid Evap Purge Solenoid - Removal.
- IAT/MAP sensor Removal.