Intake Manifold Removal
^ Tools Required- J37088-A Fuel Line Quick Connect Separator Tool Set
Caution: Refer to Battery Disconnect Caution in Service Precautions.
1. Remove the negative battery cable.
2. Remove the intake manifold sight shield-four nuts (1).
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
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.
7. Remove the accelerator cable and cruise control cable at the throttle body.
8. Disconnect the spark plug wires from the left bank spark plugs and the molded retainers in the intake manifold. Lay the wires aside.
9. Remove the throttle body coolant hoses at the throttle body and the surge tank pipe.
10. Disconnect the PCV valve and both feed tubes from the camshaft covers.
11. Disconnect the EGR and crankcase ventilation pipe at the throttle body spacer.
12. Remove the brake booster vacuum hose at the intake manifold vacuum fitting.
13. Remove the fuel rail ground wire at the rear cylinder head.
14. Disconnect the fuel rail bracket retaining bolt at the rear lift bracket.
15. Remove the quick-connect fittings at the fuel rail.
15.1. Grasp both sides of the fitting.
15.2. Twist the female connector 1/4 turn in each direction to loosen any dirt within fitting.
Caution: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.
15.3. Blow the dirt out of the fitting using compressed air.
15.4. Choose the correct tool from the J37088-A for the size of the fitting. Insert the tool into the female connector, then push/pull inward to release the locking tabs.
15.5. 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.
16. Disconnect the fuel rail bracket at the EGR valve. Refer to Fuel Rail Assembly Replacement in Powertrain Management.
17. Disconnect the injector harness main connector.
18. Remove the purge solenoid harness by removing the retaining bolt and disconnecting from the intake manifold.
19. Disconnect the throttle body heater hose from the water crossover.
20. Disconnect the generator coolant inlet hose from the heater outlet pipe and remove from the intake manifold studs.
21. Disconnect the throttle body heater outlet hose from the throttle body and remove the coolant overflow pipe from the intake manifold studs.
Important: 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.
22. Remove six bolts, four studs and the intake manifold
Important: 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.
23. Remove the four throttle body (4) to spacer (1) retaining bolts.
24. Remove the throttle body gasket (1) and discard. Make sure all gasket material is removed.
25. Remove the throttle body spacer retaining bolts (2) and throttle body spacer (1) from the intake manifold.
26. Remove the MAP sensor from the top of the spacer mounting location.
27. Disconnect the eight fuel rail snap lock retainers by squeezing the tab and lifting the fuel rail simultaneously.
28. Remove the brake booster vacuum hose.
29. Lift the entire fuel rail and injector assembly from the intake manifold when all eight snap lock retainers are released.