Removal

WARNING: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place. anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.

REMOVAL
1. Disconnect negative battery terminal.





2. Drain engine coolant. (Drains are located at right front corner of the engine block and right-hand side of radiator.)
3. Remove air inlet tube and air filter cover, disconnecting fresh air hose at cam cover.
4. Remove PCV valve hose.

CAUTION: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around fitting to collect fuel while connecting gauge. Place the cloth in an approved container.





5. Connect fuel gage bar kit to the fuel pressure test port. Use 90° adaptor.
6. Install bleed hose into an approved container and open valve to bleed system pressure. Once pressure is bled, remove gauge from fuel pressure test port and recap it.





7. Remove the bolt at fuel line clip and disconnect fuel lines from rail.
8. Disconnect supply and return fuel line from the fuel rail.





9. Disconnect throttle cable from the throttle body.
10. Remove the throttle cable bracket assembly and cable.





11. Remove the following electrical connectors and harness wiring:
a. Fuel injectors.
b. Throttle position sensor.
c. Idle Air Control valve (IAC).
d. Manifold Absolute Pressure (MAP) sensor.
e. EGR valve.
12. Disconnect heater and deaeration hoses at intake manifold outlets.





13. Lay harness over brake master cylinder.
14. Remove the intake manifold support bracket bolt attached to the intake manifold located next to the master cylinder.
15. Remove accessory drive belt.





16. Remove power steering pump assembly with support bracket. See Steering and Suspension.
17. Remove the three upper intake manifold attachment nuts.

WARNING: Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. Make sure hoist does not contact fuel or brake lines.

18. Raise vehicle squarely on a hoist. Refer to lift instructions for positioning vehicle on hoist.
19. Remove lower power steering unit support bracket.





20. Remove the intake manifold support bracket bolt attached to the intake manifold and located next to the generator. Loosen the lower bracket bolt and rotate bracket out of the way.
21. Disconnect vacuum hose at the EVAP canister purge solenoid and brake booster.
22. Remove intake manifold attaching stud.
23. Lower vehicle to floor.





24. Remove intake manifold assembly.
25. Remove intake manifold gasket and discard. Clean cylinder head and intake manifold gasket sealing surfaces.