Intake Manifold: 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.
- Drain the cooling system. For additional information, refer to ENGINE COOLING article.
- Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
- Disconnect the fuel supply hose spring lock coupling from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Remove the generator. For additional information, refer to GENERATOR AND REGULATOR article.
- Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
- Disconnect the crankcase ventilation tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Disconnect the quick connect coupling and remove the evaporative emissions system (EVAP) hose from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Disconnect the EVAP hose position retainer from the intake manifold.
- Remove the 4 bolts and the air cleaner outlet pipe-to-throttle body (TB) adapter.
- Disconnect the upper radiator and heater coolant hoses from the engine coolant crossover assembly.
- Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
- Disconnect the 8 fuel injector electrical connectors.
- Disconnect the 8 ignition coil electrical connectors.
- Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
- Disconnect the heated PCV intake fitting electrical connector.
- Remove the intake manifold vacuum tube support bracket bolt and disconnect the intake manifold vacuum tube-to-intake manifold hose.
- Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
- Disconnect the intake manifold vacuum tube support retainer from the valve cover and position the intake manifold vacuum tube aside.
- Remove the 10 intake manifold bolts.
- Remove the 3 bolts and the engine coolant crossover assembly.
- Discard the 2 gaskets.
- Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Disconnect the charge motion control valve (CMCV) electrical connector.
- 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.