FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Removal

1. Disconnect battery ground cable.
2. Drain engine cooling system.
3. Remove crankcase ventilation tube from valve cover and air cleaner outlet tube.
4. Remove aspirator hose from air cleaner outlet tube. Remove engine Air Cleaner (ACL) from throttle body and air cleaner outlet tube.
5. Carefully relieve fuel system pressure at fuel pressure relief valve.

WARNING: COVER FUEL PRESSURE RELIEF VALVE WITH SHOP CLOTH TO PREVENT ACCIDENTAL FUEL SPRAY INTO EYES.

6. Remove fuel tube safety clips. Disconnect fuel tubes.
7. Mark locations of vacuum lines and remove.
8. Disconnect engine control sensor wiring from Camshaft Position Sensor (CMP sensor), throttle position sensor, idle air control valve, Engine Coolant Temperature Sensor (ECT sensor), ignition coil, water temperature indicator sender unit, EGR backpressure transducer and EGR vacuum regulator solenoid connector.
9. Disconnect upper radiator hose from water hose connection. After loosening retaining clamp, use a twisting motion on upper radiator hose to loosen hose from water hose connection.
10. Remove upper intake manifold.
11. Loosen EGR valve to exhaust manifold tube retaining nut and remove EGR valve to exhaust manifold tube from EGR valve tube to manifold connector.
12. Disconnect engine control sensor wiring retainers from valve cover stud bolts. Carefully disconnect electrical connections to each fuel injector and position engine control sensor wiring out of the way.
13. Disconnect heater water hoses.
14. Remove ignition wires from spark plugs. Remove harness retainers to valve cover stud bolts. Remove camshaft position sensor.
16. Remove ignition coil from rear of LH cylinder head.
17. Remove valve covers.
18. Loosen cylinder No.3 intake valve rocker arm seat retaining bolt and rotate rocker arm off of push rod and away from top of valve stem. Remove push rod.
19. Remove lower intake manifold retaining bolts using a Torch head socket. Before attempting to remove intake manifold, break seal between intake manifold and cylinder block. Wedge a large pry bar or similar tool between intake manifold and cylinder block. Pry upward on tool using area between water hose connection and transaxle as a leverage point.

NOTE: Lower intake manifold may be removed with fuel injection supply manifold and fuel injectors in place as an assembly.