Removal

1. Remove windshield wiper module.
2. Perform fuel system pressure release procedure (before attempting any repairs).
3. Drain cooling system.
4. Remove air inlet resonator to throttle body hose assembly.
5. Remove throttle cable. Remove wiring harness from throttle cable bracket.





6. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body.
7. Remove EGR transducer connector.
8. Remove vacuum hose harness from throttle body.
9. Remove PCV and brake booster hoses from air intake plenum.





10. Disconnect MAP Sensor electrical connection.
11. Remove EGR tube flange from intake plenum.
12. Remove vacuum harness connectors from intake plenum.





13. Remove cylinder head to intake plenum strut.
14. Remove the engine mounted ground strap.





15. Remove the fuel hose quick connect fitting from the fuel line by using an open end wrench pushing in on the plastic ring located on the end of the fittings. Gently pull the fitting from the fuel line.

CAUTION: Wrap a shop towel around hoses to catch any gasoline spillage during removal.





16. Remove Direct Ignition System (DIS) coils and generator bracket to intake manifold bolt.





17. Remove bolts from generator to intake manifold bracket. Loosen top generator mounting bolt, and move bracket up so intake manifold can clear mounting studs.
18. Remove intake manifold bolts and remove the manifold.





19. Cover intake manifold with suitable cover when servicing.
20. Remove vacuum harness connector from Fuel Pressure Regulator.
21. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer bracket to allow fuel tube removal clearance.





22. Disconnect cam sensor and coolant temperature sensor.
23. Remove fuel injector wiring clip from intake manifold water tube.





24. Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their ports.

Intake Manifold Bolts Location And Tightening Sequence:

25. Remove upper radiator hose, bypass hose and rear intake manifold hose.
26. Remove intake manifold bolts. Remove intake manifold.
27. Inspect and clean manifold.

WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.





28. Remove intake manifold seal retainers screws. Remove intake manifold gasket.