Removal
REMOVAL1. Remove the battery negative cable.
Fig. 1 Removing / Installing Bonnet And Throttle Controls - Early:
Fig. 2 Removing / Installing Throttle Cables - Late:
2. Remove the throttle body air inlet hose Figs. 1 and 2.
3. Disconnect the transmission kick-down cable at the throttle body Figs. 1 and 2.
4. Disconnect the accelerator cable and cruise control cable connector Figs. 1 and 2.
CAUTION: Use finger pressure only to remove the cruise control connector. If the connector is broken, the whole cable must be replaced.
Fig. 3 Vacuum Hoses / TPS Connector / Idle Air Bypass Hose - Early:
Fig. 4 Vacuum Hoses / TPS Connector And Automatic Idle Speed (AIS) Motor Connections:
5. Disconnect the brake vacuum booster hose Figs. 3 and 4.
6. Disconnect the vacuum connection from the throttle body adapter Figs. 3 and 4.
7. Disconnect the Throttle Position Sensor (TPS) connector Figs. 3 and 4.
8. Disconnect the idle air- bypass hose from the throttle body adapter Figs. 3 and 4.
9. Disconnect the HVAC reservoir vacuum hose from the fitting on the throttle body adapter.
10. Disconnect the EGR tube.
Fig. 5 EGR Valve Transducer Vacuum Hose - Early:
Fig. 6 EGR Valve Transducer Vacuum Hose - Early:
11. Disconnect the EGR valve transducer vacuum hose Figs. 5 and 6.
12. Disconnect the air temperature sensor wire connector (located behind the idle air bypass hose).
13. Before disconnecting the fuel injector wire harness, tag each connector with the number of its corresponding injector.
Fig. 7 Injector Harness And CCV Vacuum Hose:
14. Disconnect the fuel injector wire harness from the injectors and lay to the side Fig. 7.
15. Disconnect the CCV vacuum hose from the fitting between Nos. 2 and 3 runners Fig. 7.
16. Remove the fuel tank filler cap to relieve the fuel tank pressure.
17. Install the fuel tank filler cap.
Fig. 8 Disconnect Fuel Lines Using Disconnect Special Tool 6182:
18. Place shop towels under the fuel tubes. Disconnect the fuel supply tube from the fuel rail and the fuel return tube from the fuel pressure regulator using disconnect special tool 6182 Fig. 8. Slide the tool onto the nipple and push it forward into the quickconnector until the handle stops on the connector casing. Pull the fuel tubes off.
19. Move the tubes to the side being careful not to kink the fuel tubes.
Fig. 9 Intake Manifold Mounting Bolts:
20. Loosen the intake manifold mounting bolts Fig. 9.
21. Remove the intake manifold.
22. Remove and replace the O-rings in the cylinder heads.