Removal

Intake Manifold





Material

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. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Drain the engine cooling system.
4. Remove the air cleaner outlet tube.
5. Remove the generator.
6. Disconnect the fuel tube spring lock couplings.





7. Compress and slide the hose clamp and disconnect the coolant outlet hose.





8. Remove the accelerator cable splash shield.





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





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





11. Disconnect the Positive Crankcase Valve (PCV) tube and the vacuum tubes.





12. Disconnect the heated PCV coolant hose.





13. Disconnect the vacuum tube.





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





15. Disconnect the Idle Air Control (IAC) motor electrical connector and the bypass hose.





16. Disconnect the heater hose.





17. Disconnect the five LH fuel injector Throttle Position (TP) sensor electrical connectors and ignition coil connectors.





18. Remove the ignition coils.
^ Remove the 10 bolts.
^ Remove the 10 ignition coils.

19. Disconnect the vacuum connector from the fuel pressure regulator.
20. Remove the bolts and the thermostat and housing.





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

22. 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.
^ Clean the intake manifold mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.