Removal-Lower Intake Manifold

1. Install memory saver then disconnect the battery negative cable.

2. Drain the cooling system.

3. Remove the air cleaner outlet tube as follows:

^ Disconnect the intake air temperature sensor.

^ Disconnect the crankcase fresh air tube.

^ Loosen the air cleaner outlet tube clamps at the mass airflow sensor and the throttle body.

^ Remove the air cleaner outlet tube.

4. Disconnect the accelerator and speed control cables from the throttle body, then remove the throttle return spring.

5. Remove the retainers from the accelerator cable bracket and position the bracket and cables out of the way.





6. Disconnect the throttle position sensor. See Figure 1.

7. Disconnect the evaporative emissions hose from the upper intake manifold. See Figure 1.

8. Disconnect the idle air control valve. See Figure 1.

9. Disconnect the two (2) hoses and the electrical connector from the Differential Pressure Feedback EGR (DPFE). See Figure 1.





10. Disconnect the vacuum hoses from the top of the intake manifold and the EGR valve. See Figure 2.

11. Disconnect the vacuum hoses and the electrical connector from the EGR vacuum regulator solenoid. See Figure 2.

12. Disconnect the EGR tube at the EGR valve. See Figure 2.

13. Remove the PCV valve and tube as an assembly. See Figure 2.





14. Remove the upper intake manifold retainers in the sequence shown, then remove the manifold and gasket. See Figure 3.

15. Release the fuel system pressure as follows:

^ Remove the Schrader valve cap and attach an EFI/CFI fuel pressure gauge.

^ Slowly open the manual valve an the fuel pressure gauge to relieve fuel system pressure.

^ Install the cap on the Schrader valve.

16. Disconnect the fuel line.

17. Disconnect the upper and lower radiator hoses from the bypass tube.

18. Disconnect the coolant temperature sensor.

19. Remove the bypass tube.

20. Remove the accessory drive belt tensioner stop.

21. Remove the accessory drive belt.

22. Remove the accessory drive belt tensioner.

23. Disconnect all alternator connections.

24. Remove the upper alternator bracket.

25. Loosen the lower alternator bolts, then lift and remove the alternator.

26. Disconnect the vacuum hose and the electrical connector from the fuel pressure regulator.

27. Disconnect the fuel injectors.





28. Detach the fuel charge wiring harness from the fuel manifold studs and remove the tie strap securing the harness to the fuel manifold. See Figure 4.

CAUTION
Clean any debris from the manifold/cylinder head mating surfaces before removing the manifold. Failure to clean this area may result in debris entering the intake ports of the cylinder heads.





29. Remove the lower intake manifold retainers in the sequence shown. See Figure 5.

CAUTION:
The engine control harness pushpin is difficult to reach. When accessing the pushpin, do not bend the EGR tube or allow the tube to scratch the gasket mating surfaces of the manifold.

30. Position the lower intake manifold forward and detach the engine control harness pushpin from the back of the manifold. See Figure 5.

31. Remove the lower intake manifold and gaskets. Discard the gaskets.

NOTE:
Do not detach fuel injectors from the fuel manifold.

32. Remove the fuel manifold stud bolts, then remove the fuel manifold and injectors as an assembly.