Removal

REMOVAL

1. Install memory saver, then disconnect battery ground cable.

2. Remove cover from throttle body.

3. Drain cooling system.

4. Relieve fuel system pressure as follows:

^ Connect Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B to fuel pressure relief valve on the fuel supply manifold.

^ Open manual valve on gauge to relieve fuel system pressure.

^ Remove gauge from relief valve.

5. Remove air cleaner outlet tube.

6. If equipped with ignition wires, disconnect the ignition wires from spark plugs and routing clips. If equipped with a coil-on-plug system, disconnect and remove individual coils from each cylinder.

7. Remove PCV valve and hose from engine.





8. Disconnect fuel charge wiring harness from right side fuel injectors, Engine Coolant Temperature (ECT) sender and EGR Vacuum Regulator (EVR) solenoid.See Figure 2. Position right side fuel charge wiring harness away from intake manifold.





9. Disconnect heater hose from right rear corner of intake manifold. See to Figure 3.

10. Remove throttle/speed control cable routing bracket. See to Figure 3.

11. Disconnect EGR tube from EGR valve. See to Figure 3.

12. Disconnect vacuum line from EVAP solenoid. See Figure 3.

13. Disconnect two (2) vacuum lines from top of throttle body adapter.





14. Disconnect main engine wiring harness pushpin from rear of intake manifold. See Figure 4.

15. Remove drivebelt from alternator.

16. Remove retainers from alternator upper support bracket, then slightly raise bracket. Refer to Figure 5.





17. Disconnect all alternator electrical connectors. See Figure 5.

18. Position alternator upper support bracket and ignition wires (if equipped) away from intake manifold.

19. Detach alternator wiring harness from intake manifold~ then position wiring harness aside.

20. Remove alternator from vehicle.

21. Disconnect radiator hose from thermostat housing.





22. Disconnect throttle and speed control cables from throttle body.See to Figure 6. Position cable away from intake manifold.

23. Disconnect fuel charge wiring harness from left side fuel injectors, Engine Coolant Temperature (ECT) sensor and retaining stud. See to Figure 6.

24. Disconnect fuel lines at spring clips. See Figure 6.





25. Detach two (2) wiring harnesses from clip on left rear of intake manifold. See Figure 7. Push both harnesses toward bulkhead clearing intake manifold.

26. Disconnect Throttle Position (TP) sensor electrical connector.

27. Disconnect Idle Air Control (IAC) sensor electrical connector.





28. Unclip fuel charge wiring harness from studs on left side valve cover. Position wiring harness away from intake manifold. See Figure 8.

29. Remove intake manifold retaining bolts.

30. With an assistant's help, remove intake manifold assembly.