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Intake Manifold: Removal

NOTE: Care must be taken to protect the intake manifold powder coating from scrapes and abrasions.
  1. Perform the fuel system pressure release procedure, before attempting any repairs. (Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE) .
  2. Open trunk lid. Remove battery cover. Disconnect negative battery cable.
  3. Disconnect throttle body air inlet hose, IAT sensor, and remove air cleaner housing assembly (Refer to AIR CLEANER HOUSING ).
  4. Disconnect throttle cable from throttle cam. Remove throttle cable from bracket and set aside. See Fig 1.
    Fig 1: THROTTLE BODY AND THROTTLE CABLE
    GC0004085Courtesy of DAIMLERCHRYSLER CORP.
  5. Disconnect brake booster vacuum hose from the intake manifold and set aside.
    WARNING: WRAP A SHOP TOWEL AROUND FUEL LINE TO CATCH ANY GASOLINE SPILLAGE.
  6. Disconnect fuel line quick connect fitting from fuel rail (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) . See Fig 2.
    Fig 2: Fuel Line Connection
    GC0004075Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the wiper arms (Refer to ELECTRICAL/WIPERS/WASHERS/WIPER ARMS - REMOVAL) .
  8. Remove the wiper cowl (Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL) .
  9. Disconnect the following electrical connectors:
    1. Left cylinder head fuel injectors
    2. MAP sensor
    3. Engine Coolant Temperature (ECT) Sensor
    4. Idle Speed Control Sensor (ISC)
    5. Throttle Position Sensor (TPS)
    6. Right cylinder head fuel injectors
  10. Carefully separate the fuel injector harness push pins from the intake manifold.
  11. Unclip coolant bottle inlet hose from throttle body bracket and disconnect the purge solenoid hose from beneath the throttle body. See Fig 3. Do Not   disconnect coolant bottle inlet hose.
    Fig 3: COOLANT BOTTLE INLET HOSE
    GC0004089Courtesy of DAIMLERCHRYSLER CORP.
    1 - COOLANT BOTTLE INLET HOSE
  12. Disconnect CCV hoses from left and right cylinder head covers.
    CAUTION: Care must be taken when removing the number nine cylinder inside intake manifold bolt. Failure to do so may result in personal injury or possible damage.
  13. Remove the intake manifold bolts and intake manifold. See Fig 4.
  14. Cover the intake manifold openings with a suitable cover when servicing to prevent any debris from entering cylinder heads.
Fig 4: Intake Manifold and Gasket
GC0004090Courtesy of DAIMLERCHRYSLER CORP.
1 - INTAKE MANIFOLD GASKET
2 - INTAKE MANIFOLD
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