Submitted by: Quik LS

A little more involved, removing the V8 intake requires draining the cooling system and removing the Air Cleaner Outlet Tube - both are described in other tech articles.



REMOVAL
1. Disconnect the battery ground cable.

2. Remove the air cleaner outlet tube.

image001.gif
CAUTION: The coolant drain procedure must be followed exactly or damage to the engine may occur.


Drain the engine cooling system.

4. Remove the cowl vent screen.

5. Remove the engine compartment brace.

image002.gif


6. Disconnect the accelerator and speed control cables.

image003.gif


7. Disconnect the vacuum hoses.

image004.gif


8. Disconnect the vacuum line.

image005.gif


9. Disconnect the EGR valve to exhaust manifold tube

image006.gif


10. Remove the EGR valve.

  • A. Remove the two bolts.
  • B. Remove the valve and discard the gasket.
image007.gif


11. Disconnect the camshaft position (CMP) sensor electrical connector and separate the connector from the fuel injection supply manifold.

image008.gif


image001.gif
CAUTION: To remove normal fittings, squeeze the tabs and pull straight out or damage to the fitting may occur.

Disconnect the evaporative emission canister purge valve line.

image009.gif



13. Disconnect the fuel pressure sensor electrical connector.

image010.gif




14. Disconnect the vacuum connector from the fuel pressure sensor.

image011.gif




15. Disconnect the fuel line.

16. Remove the electrical connectors from the bracket.

  • 1. LH knock sensor (KS).
  • 2. Cylinder head temperature (CHT) sensor.
image012.gif


17. Remove the nut and the bracket.

image013.gif



18. Remove the bracket.

  • 1. Remove the hose.
  • 2. Remove the nuts and the bracket.
image014.gif



19. Raise the engine wiring harness and disconnect the LH fuel injector connectors.


image015.gif






20. Disconnect the electrical connectors.

  • · Idle air control (IAC) valve.
  • · Throttle position (TP) sensor.
image016.gif



21. Disconnect the crankcase ventilation tube from the RH valve cover.

image017.gif



22. Disconnect the hoses (1) from the throttle body and the retaining clips (2).

image018.gif




23. Raise the engine wiring harness and disconnect the RH fuel injectors.

image019.gif



24. Remove the Delta PFE sensor.

  • 1. Disconnect the electrical connector.
  • 2. Disconnect the hoses.
  • 3. Remove the bolts and the sensor.

image020.gif






25. NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold. Remove the bolts and the stud (2) in the sequence shown.

image021.gif



26. NOTE: The throttle body, adapter and EGR valve are shown removed for clarity. NOTE: Position the throttle body heater return hose out of the way before removing the throttle body.



Remove the intake manifold.

image022.gif




image001.gif
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to clean the surfaces.


Clean the sealing surfaces.
  • Inspect the gaskets and install new gaskets if necessary.

image023.gif





Installation
1. If removed, install the gaskets.

image024.gif



2. NOTE: Make sure that the throttle body heater return hose is positioned between the heat shield and the intake manifold.

Install the intake manifold and tighten the bolts in the sequence shown.

image025.gif




3. Install the Delta PFE sensor.
  • 1. Install the sensor and the bolts.
  • 2. Connect the electrical connector.
  • 3. Connect the hoses.
image026.gif


4. Connect the RH fuel injectors and position the engine wiring harness.

image019.gif


5. Connect the hoses (1) and install the hose in the clip (2).

image018.gif




6. Connect the crankcase ventilation tube.

image017.gif



7. Connect the IAC valve and TPS electrical connectors.

image016.gif



8. Connect the LH fuel injector connectors and position the engine wiring harness.

image015.gif




9. Install the bracket.
  • 1. Install the bracket and nuts.
  • 2. Install the hose.
image027.gif



10. Install the bracket and the nut.

image028.gif



11. Install the electrical connectors on the bracket.
  • 1. Install the LH KS connector.
  • 2. Install the CHT sensor connector.
image012.gif




12. Connect the fuel line.

13. Connect the vacuum connector to the fuel pressure sensor.

image011.gif



14. Connect the fuel pressure sensor electrical connector.

image010.gif



15. Connect the evaporative emission canister purge valve line.


image009.gif




16. Connect the CMP sensor electrical connector and position the connector on the fuel injection supply manifold.

image008.gif



17. Connect the EGR valve to exhaust manifold tube.

image006.gif



18. NOTE: EGR valve to exhaust manifold tube is removed for clarity.
  • Install the EGR valve.
  • 1. Install a new gasket and the valve.
  • 2. Install the two bolts.
image029.gif




19. Tighten the tube.

image030.gif



20. Connect the vacuum line.

image005.gif



21. Connect the vacuum hoses.

image004.gif




22. Connect the accelerator and speed control cables.

image003.gif



23. Install the engine compartment brace.

image031.gif



24. Install the cowl vent screen.

25. Install the air cleaner outlet tube. .

26. Connect the battery ground cable.

image001.gif
CAUTION:
The cooling system filling and bleeding procedure must be followed exactly or damage to the engine may occur.

Fill and bleed the engine cooling system.