To remove the intake manifold, first disconnect the cable from the negative terminal of the battery, ensuring you have the correct activation code for the radio if it has an anti-theft system. Drain the cooling system, then remove the intake air duct and air cleaner housing. Clearly label and detach any vacuum lines and electrical connectors that may interfere with the manifold removal, and detach the accelerator cable from the throttle lever. Remove the coolant hoses from the throttle body, relieve the fuel system pressure, and disconnect the fuel feed and return lines at the fuel rail. From underneath the engine compartment, remove the brace that supports the intake manifold by taking out the bolts. Disconnect the coolant by-pass hose from the intake manifold, then remove the intake manifold nuts and take the manifold off the engine. For installation, clean the manifold nuts with solvent and dry them with compressed air if available. Check the mating surfaces of the manifold for flatness using a precision straightedge and feeler gauges, and inspect the manifold for cracks and distortion, replacing it if necessary. Carefully check for any stripped or broken intake manifold bolts or studs and replace any defective bolts with new parts. Use a scraper to remove all traces of old gasket material from the cylinder head and manifold mating surfaces, then clean the surfaces with lacquer thinner or acetone. Install the intake manifold with a new gasket, tightening all the nuts finger-tight, and then follow the recommended sequence to tighten the nuts to the specified torque. The remainder of the installation process is the reverse of the removal steps.
