Intake Manifold: Removal
WARNING: This page is about a different car, the 1995 Plymouth Voyager, 1995 Plymouth Grand Voyager, 1995 Dodge Grand Caravan, and 1995 Dodge Caravan. However, it is still accessible from the selected car via links, so may be relevant.
- Perform fuel line purging. See FUEL LINE PURGING .
- Disconnect negative battery cable. Drain cooling system. Remove air cleaner-to-throttle body hose.
- Disconnect control cables and electrical connections from throttle body. Disconnect necessary vacuum hoses from throttle body and intake manifold.
- Disconnect vacuum hoses and EGR tube flange from air intake plenum (upper intake manifold). Disconnect necessary electrical connections for intake manifold removal. Remove cylinder head-to-air intake plenum support brace.
- Disconnect necessary fuel lines using proper procedure. See FUEL LINES & FITTINGS .
- Remove ignition coils and alternator bracket from air intake plenum. Remove air intake plenum bolts. See Fig 1. Rotate air intake plenum back over valve cover. Cover intake manifold ports with shop towels.
- Disconnect electrical connectors at fuel temperature and fuel pressure sensors located on fuel rail.
- Disconnect fuel injector wiring harness from engine wiring harness. Disconnect necessary sensor wiring connectors, near fuel rail and intake manifold. Remove fuel rail bolts.
- Fuel rail consists of 3 sections. Sections cannot be separated, although one section will rotate within the other.
- Gently rock and pull upward on rear section of fuel rail until fuel injectors clear the intake manifold. Gently rock and pull upward on front section of fuel rail until fuel injectors clear the intake manifold. Remove fuel rail along with fuel injectors.CAUTION: Handle intake manifold gasket carefully as gasket contains sharp edges.
- Disconnect coolant hoses at intake manifold. Remove intake manifold bolts in sequence. See Fig 2. Remove intake manifold. Remove intake manifold gasket end seal retaining screws, and remove gasket.