Removal
Intake Manifold Components:
REMOVAL
1. Disconnect negative battery cable.
2. Drain cooling system.
3. Relieve fuel system pressure and disconnect fuel lines.
4. Remove wiper module.
5. Remove air inlet tube.
6. Release belt tensioner and remove accessary drive belt.
7. Disconnect all ignition plug wires from spark plugs.
CAUTION: Do not pull on ignition wires.
8. Disconnect ignition wire brackets from camshaft cover studs.
9. Disconnect both ignition coils and Camshaft Position (CMP) sensor.
10. Disconnect all ignition wires from both ignition coils.
11. Remove two bolts retaining ignition wire tray to coil brackets.
12. Remove ignition wire assembly.
13. Disconnect alternator wiring harness from junction block, fender apron and alternator.
14. Remove two bolts retaining alternator brace to intake manifold.
15. Remove two bolts retaining alternator to engine block and remove alternator.
16. Raise vehicle on a hoist.
17. Disconnect oil sending unit and EVO harness sensor and position wiring harness out of the way.
18. Disconnect EGR tube from RH exhaust manifold.
19. Lower vehicle.
20. Remove 42-pin engine harness connector from retaining bracket on vacuum brake booster.
21. Disconnect 42-pin connector.
22. Disconnect air conditioning compressor, HDR sensor and canister purge solenoid.
23. Remove PCV valve from camshaft cover and disconnect canister purge vent hose from PCV valve.
24. Disconnect accelerator and seed control cables from throttle body using a screwdriver or similar tool.
Accelerator And Speed Control Cable:
25. Remove accelerator cable bracket from intake manifold and position out of the way.
26. Disconnect throttle valve cable from throttle body.
27. Disconnect vacuum hose from throttle body vacuum port.
28. Disconnect both HO2S sensors.
29. Disconnect heater supply hose.
30. Remove two bolts retaining thermostat housing to intake manifold and position upper hose and thermostat housing out of the way.
NOTE: Two thermostat housing bolts also retain intake manifold.
31. Remove nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
32. Remove intake manifold gaskets.