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.

1. Disconnect negative battery terminal.





2. Drain engine coolant. (Drains are located at right front corner of 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.

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





5. Connect fuel gage bar kit to fuel pressure test port.
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 from fuel line clip and disconnect fuel lines from rail.





8. Disconnect supply and return fuel lines from the fuel rail.





9. Disconnect throttle cable from the throttle body.
10. Remove throttle cable bracket attaching nuts.





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





13. Lay harness over brake master cylinder.
14. Remove the intake manifold support bracket bolt attached to the intake manifold located below the throttle body.

NOTE: Label vacuum lines to make sure they are replaced properly.

15. Remove accessory drive belt.





16. Remove power steering pump assembly. Remove power steering pump bracket attachment bolts and position pump next to the right-hand front of dash panel, away from the cylinder head and intake manifold. See Steering and Suspension.
17. Remove the four 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. Disconnect vacuum hose at the EVAP canister purge solenoid and brake booster.
20. Remove 5 lower intake manifold attaching nuts.
21. Lower vehicle to floor.





22. Remove intake manifold assembly.
23. Remove intake manifold gasket and discard. Clean cylinder head and intake manifold gasket sealing surfaces.