Intake Manifold: Removal
WARNING:
Do not smoke or carry lighted tobacco or 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 personal injury.
WARNING:
Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
- Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
- Drain the cooling system. For additional information, refer to ENGINE COOLING .
- Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
- Remove the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
- Disconnect the upper radiator hose from the thermostat housing.
- Disconnect the heater coolant hose from the coolant bypass tube.
- Disconnect the evaporative emissions system (EVAP) tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
- Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
- Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
- Disconnect the 8 fuel injector electrical connectors.
- Disconnect the 4 LH ignition coil electrical connectors.
- Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
- Disconnect the LH radio ignition interference capacitor electrical connector.
- Disconnect the camshaft position (CMP) sensor electrical connector.
- Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
- Disconnect the engine oil pressure (EOP) sensor electrical connector.
- Disconnect the LH heated exhaust gas oxygen sensor (H02S) electrical connector and detach the electrical connector retainer.
- Disconnect the heated PCV intake fitting electrical connector.
- Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
- Disconnect the LH engine wiring harness retainers from the LH valve cover studs and position aside.
- Remove the 10 intake manifold bolts
- Remove the 3 bolts, the coolant bypass tube and discard the gaskets.
- Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Position the intake manifold assembly forward to gain access to the remaining electrical connectors.
- Disconnect the charge motion control valve (CMCV) electrical connector.
- Disconnect the manifold vacuum tube from the valve cover stud and the support bracket.
- Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
- Disconnect the LH and RH knock sensor (KS) electrical connectors.
- Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.
- Remove the intake manifold and discard the gaskets.
- Inspect and clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
CAUTION:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
CAUTION:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.