Intake Manifold: Removal

Perform the fuel system pressure release procedure, before attempting any repairs. (Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE ).
Open trunk lid. Remove battery cover. Disconnect negative battery cable.
Disconnect throttle body air inlet hose, remove air cleaner housing assembly (Refer to AIR CLEANER ELEMENT ).
Disconnect throttle cable from throttle cam. Remove throttle cable from bracket (Fig 1).

Fig 1: Disconnecting Throttle Cable at Throttle Body
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect brake booster vacuum hose and evaporative emission harness hoses.
Disconnect the following electrical connectors:
- Oil Pressure Sensor
- Oil Temperature Sensor
- Generator Field (2 way)
- Inlet Air Temperature (IAT) Sensor
- Engine Coolant Temperature (ECT) Sensor
- Camshaft Position Sensor
- PCM Connectors
- Body Harness Connector (Left Frame Rail Area)
WARNING: WRAP A SHOP TOWEL AROUND FUEL LINE TO CATCH ANY GASOLINE SPILLAGE.
Disconnect fuel line quick connect fitting from fuel rail (Refer to QUICK CONNECT FITTING - STANDARD PROCEDURE ) (Fig 2).

Fig 2: Identifying Fuel Line Connection
Courtesy of DAIMLERCHRYSLER CORP.
Unclip coolant bottle inlet hose from throttle body bracket (Fig 3). Do Not disconnect coolant bottle inlet hose.

Fig 3: Unclipping Coolant Bottle Inlet Hose
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect CCV hoses from left and right cylinder head covers.
Remove the intake manifold bolts.
Partially lift intake manifold and disconnect ignition coil connectors.
Remove intake manifold with engine/injector wiring harness (Fig 4).

Fig 4: Removing Intake Manifold And Gasket
Courtesy of DAIMLERCHRYSLER CORP.
Cover the intake manifold openings with a suitable cover when servicing to prevent any debris from entering cylinder heads.