Intake Manifold Removal

INTAKE MANIFOLD REMOVAL PROCEDURE





1. Remove the intake manifold sight shield (1).





2. Disconnect the spark plug wires from the left bank spark plugs and the molded retainers in the intake manifold. Lay the wires aside.





3. Disconnect the dirty air PCV tube (1) from the PCV valve (2) and the intake manifold.
4. Remove the dirty air PCV tube.





5. Disconnect the fresh air PCV tube (1) from the camshaft cover and the intake manifold.
6. Remove the fresh air PCV tube.





7. Disconnect the EGR and crankcase ventilation pipe at the throttle body spacer.





8. Disconnect the fuel rail ground wire at the rear cylinder head.





9. Disconnect the fuel rail bracket (1) retaining bolt (3) at the rear lift bracket (4).





10. Remove the purge solenoid harness by removing the retaining bolt and disconnecting from the intake manifold.





11. Disconnect the throttle body heater hose (3) from the water crossover (4).





12. Disconnect the generator coolant inlet hose (1) from the throttle body heater outlet pipe and remove the tube (2) from the intake manifold studs.





13. Disconnect the throttle body heater outlet hose (1) from the throttle body (3) and remove the coolant overflow pipe (5) from the intake manifold studs (4).





14. Loosen and remove the intake manifold studs (1), spacers (2) and bolts (3).
15. Remove the intake manifold assembly.

IMPORTANT: The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When you remove the intake manifold, the carrier gaskets will remain attached to the manifold. It is not necessary to replace the gaskets unless there is damage to the seals.

INTAKE MANIFOLD DISASSEMBLY PROCEDURE

IMPORTANT: The following steps are only necessary if the throttle body or intake manifold require replacement.





1. Remove the four throttle body (4) to spacer (1) retaining bolts (3).





2. Remove the throttle body gasket (1) and discard. Make sure all gasket material is removed from the throttle body (3).





3. Remove the MAP sensor from the top of the spacer mounting location.





4. Remove the throttle body spacer retaining bolts (1) and throttle body spacer (1) from the intake manifold.





5. Disconnect the electrical connector from each fuel injector.
6. Remove the fuel injector wire harness.





7. Disconnect the fuel regulator vacuum tube.





8. Remove the brake booster vacuum hose.





9. Disconnect the eight fuel rail snap lock retainers by squeezing the tab and lifting the fuel rail simultaneously.





10. Lift the entire fuel rail and injector assembly from the intake manifold when all eight snap lock retainers are released. Keep the fuel rail ground wire (1) clear of the manifold.