Intake Manifold: Removal
- Release fuel pressure and disconnect fuel lines. See, in this article, FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS .
- Drain cooling system. Remove air intake tubing. Remove wiper motor assembly from firewall. Release belt tensioner and remove accessory drive belt. Disconnect spark plug wires at spark plugs. Disconnect spark plug wires from camshaft cover studs.
- Disconnect wiring from both ignition coils. Disconnect Cylinder Identification (CID) sensor wiring. The CID sensor is mounted on front cover, in front of left camshaft sprocket. See Figure.
- Remove 2 ignition wire tray-to-ignition coil brackets bolts. Remove spark plug wire assembly from above intake manifold.
- Disconnect alternator wiring harness from junction block, fender apron and alternator. Remove alternator brace-to-intake manifold bolts. Remove alternator-to-cylinder block bolts. Remove alternator.
- Raise and support vehicle. Disconnect oil sending unit and Electronic Variable Orifice (EVO) sensor harness. Position wiring harness aside. Disconnect EGR tube from right exhaust manifold.
- Lower vehicle. Remove 42-pin wiring harness connector from retaining bracket on vacuum booster and disconnect connector. Refer to Figure. Disconnect necessary electrical connections, coolant hoses and vacuum hoses.
- Remove PCV valve from camshaft cover. Disconnect canister purge vent hose from PCV valve. Disconnect control cables from throttle body.
- Remove accelerator cable bracket from intake manifold and secure aside. Remove thermostat housing retaining bolts. Remove thermostat housing with upper radiator hose attached and secure aside.CAUTION: Thermostat housing bolts are also used to retain intake manifold.
- Remove retaining bolts, intake manifold and gaskets. If removing fuel rail and fuel injectors, remove fuel rail retaining bolts. Lift fuel rail and fuel injectors from cylinder head. Refer to Fig 1.
CAUTION:
DO NOT
allow fuel injectors to fall from fuel rail during removal.
CAUTION:
Intake manifold bolts must be retorqued to specification after engine has reached normal operating temperature.