Removal

TOOL REQUIRED
^ J 37088 Fuel Line Quick Connect Separator Tool Set

1. Remove the negative battery cable.





2. Remove the intake manifold sight shield-four nuts.
3. Relieve the fuel system pressure. See Fuel Pressure Release Procedure.
4. Remove the air intake duct from the throttle body.
5. Remove the transaxle vent hose and transaxle shift cable at the bracket.
6. Remove the TP sensor and IAC valve connectors. See Powertrain Management.
7. Remove the accelerator cable and cruise control cable at the throttle body. See Powertrain Management.
8. Remove the front bank spark plug wires and lay them aside.
9. Remove the throttle body coolant hoses at the throttle body and the surge tank pipe. See Powertrain Management.
10. Remove the EGR pipe and the crankcase ventilation pipe at the throttle body spacer. See Powertrain Management.
11. Remove the brake booster vacuum hose at the intake manifold vacuum fitting.
12. Remove the fuel rail ground wire at the rear cylinder head.
13. Remove the quick-connect fittings at the fuel rail.
a. Grasp both sides of the fitting.
b. Twist the female connector 1/4 turn in each direction to loosen any dirt within fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

c. Blow the dirt out of the fitting using compressed air.
d. Choose the correct tool from the Fuel Line Quick Connect Separator Tool Set for the size of the fitting. Insert the tool into the female connector, then push/pull inward to release the locking tabs.
e. Pull the connection apart.
^ Using a clean shop towel, wipe off the male pipe end.
^ Inspect both ends of the fitting for dirt and burrs.
^ Clean or replace the components or assemblies as required.
14. Disconnect the fuel rail bracket at the EGR valve. See Powertrain Management.
15. Disconnect the PCV hose at the intake manifold.
16. Disconnect the injector harness main connector.

CAUTION: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When removing the intake manifold, the carrier gaskets will remain attached to the manifold.





17. Remove six bolts, four studs and the intake manifold.
18. If replacing intake manifold, perform the following steps:
a. Remove the fuel rail. See Powertrain Management.

CAUTION: Do not replace the intake manifold gaskets after intake manifold removal. The gaskets are reusable. The gaskets should only be replaced if the plastic housing or rubber seals are damaged.





b. Remove the intake manifold carrier gaskets from the intake manifold.
c. Remove the throttle body. See Powertrain Management.
d. Remove MAP Sensor.