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.

1. Disconnect the battery ground cable.
2. Drain the coolant system.
3. Remove the air cleaner outlet tube.





4. Compress and slide the hose clamp and disconnect the water outlet hose.





5. Remove the accelerator cable splash shield.
6. Relieve the fuel system pressure.





7. Disconnect the accelerator and speed control cables and remove the return spring.





8. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the bracket and cables aside.





9. Disconnect the PCV vacuum and coolant hoses.





10. Disconnect the vacuum lines:
^ brake booster
^ engine sensor control wiring harness





11. Remove the bolt (RH) and position the radio interference capacitor aside.





12. Disconnect the vacuum line.





13. Disconnect the five RH fuel injector electrical connectors and five ignition coil electrical connectors.





14. Disconnect the idle air control motor electrical connector and the bypass hose.





15. Disconnect the heater hose.





16. If equipped, disconnect the EGR transducer and disconnect the throttle position sensor connectors.





17. If equipped, disconnect the EGR transducer vacuum lines.





18. If equipped, remove the EGR transducer bracket.





19. If equipped, position the EGR valve to exhaust manifold tube aside.
^ Disconnect the upper fitting.
^ Loosen the lower fitting.
^ Position the tube aside.





20. If equipped, disconnect the EGR valve vacuum line.





21. NOTE: The EGR valve is shown removed for clarity.

If equipped, disconnect the EVR solenoid electrical and vacuum harness.





22. NOTE: The idle air control valve is shown removed for clarity.

Remove the throttle body adapter.
^ Remove the four bolts.
^ Remove the throttle body adapter.
^ Remove the throttle body adapter gasket.





23. If equipped, remove the EVR bracket.
^ Remove the bolts.
^ Remove the bracket.





24. Disconnect the five LH fuel injector electrical connectors and ignition coil connectors.





25. Disconnect.the water temperature indicator sender unit electrical connectors.
26. Remove the generator (GEN).





27. Remove the ignition coils.
^ Remove the 10 bolts.
^ Remove the 10 ignition coils.
28. Disconnect the fuel injection supply manifold.
^ Disconnect the fuel lines.
^ Disconnect the vacuum connector from the fuel pressure regulator.





29. Remove the bolt and position the capacitor aside.





30. Disconnect the cylinder head temperature sensor.
31. Remove the water thermostat and housing.





32. Remove the bolts, the upper intake manifold and the intake manifold gaskets. Discard the intake manifold gaskets.





33. If necessary, remove the fuel injection supply manifold.
^ Remove the four bolts.
^ Remove the fuel injection supply manifold.





34. Separate the upper and lower intake manifolds.
^ Remove the 10 bolts.

35. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths.

Clean all mating surfaces.