Part 1

Intake Manifold





Crankcase Ventilation Tube, Heater Coolant Hose and Upper Radiator Coolant Hose









Generator Support Bracket and Transmission Fluid Filler Tube Support Bracket Bolt









Electrical Connectors, Vacuum Tube and Evaporative Emission (EVAP) Purge Valve Tube Quick Connect Coupling









EGR System Module-To-Exhaust Manifold Tube, EGR System Module and Throttle Body (TB)









Thermostat Housing, Thermostat, Intake Manifold and Gaskets









Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Disconnect the battery ground cable. For additional information, refer to Battery.

2. Remove the engine cover.

3. Remove the Air Cleaner (ACL) assembly and the ACL outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.

4. Drain the cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.

5. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.

6. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Fuel Delivery and Air Induction.

7. Remove the front transmission fluid filler tube support bracket bolt.

8. Remove the rear transmission fluid filler tube bolt and position the transmission fluid filler tube aside.





9. If equipped, disconnect the auxiliary heater hoses and position them aside. For additional information, refer to Heating and Air Conditioning.





10. Disconnect the Electronic Throttle Control (ETC) electrical connector and the wiring harness retainer.

11. Remove the 4 Throttle Body (TB) bolts, the TB and TB gasket.
- Discard the TB gasket.

12. Disconnect the electrical connector and the Evaporative Emission (EVAP) canister-to-EVAP canister purge valve tube quick connect coupling from the EVAP purge valve. For additional information, refer to Fuel Delivery and Air Induction.

13. Disconnect the brake booster vacuum hose from the intake manifold.

14. Disconnect the EGR system module vacuum connector and position the vacuum tube assembly aside.

15. Disconnect the EGR system module electrical connector.

16. Disconnect the upper and lower fittings and remove the exhaust manifold-to-EGR system module tube.

17. Remove the 2 bolts and the EGR system module.
- Discard the EGR system module gasket.

18. Remove the 8 ignition coils. For additional information, refer to Ignition System.

19. Remove the 4 bolts and the generator support bracket.

20. Disconnect the heater coolant hose and position aside.

21. Disconnect the 8 fuel injector electrical connectors.

22. Disconnect the Knock Sensor (KS) electrical connector, electrical connector retainer and the 2 engine wiring harness retainers from the rear of the intake manifold.





23. Disconnect the upper radiator coolant hose and position aside.

24. Remove the 2 thermostat housing bolts and the thermostat housing and discard the O-ring seal.

25. Remove the thermostat.

26. Remove the 9 intake manifold bolts.

27. Remove the intake manifold through the passenger compartment and discard the RH and LH intake manifold gaskets.