:	May 11, 2004

.

Secure the hood in the service position.   Release the support struts.

.

Disconnect the battery ground cable.

.

Remove the throttle body gasket.

.

Remove the engine cover brackets.   Release the electrical connectors from the engine cover brackets.   Remove the 4 nuts.

.

: Before the disconnection or removal of any components, ensure the area around joint faces and connections are clean. Plug any open connections to prevent contamination. Disconnect the crankcase vent hoses.

.

Disconnect the evaporative emission hose from the intake manifold assembly.

.

Release the evaporative loss control valve from the intake manifold mounting, move the hose assembly aside for access.

.

Release the fuel pipe from the clips.

.

Using the special tool, disconnect the fuel line.   Position an absorbent cloth to collect fluid spillage.

.

Release the camshaft position (CMP) sensor connector block from the intake manifold assembly.

.

Position the wiring harness support bracket aside for access.   Remove the 2 bolts.

.

Release the EGR valve.   Remove the 2 bolts.   Discard the gasket.

.

Release the engine wiring harness clips from the fuel rail.

.

Disconnect the fuel injector electrical connectors.

.

Disconnect the fuel temperature sensor electrical connector.

.

Remove the 10 intake manifold bolts.

.

Remove the intake manifold.   Disconnect the mass air flow (MAF) sensor electrical connector.   Disconnect the brake booster vacuum hose from the intake manifold.   Discard the gaskets.

.

:   Do not disassemble further if the component is removed for access only. Remove the NVH pad from the RH side of the intake manifold.

.

Remove the intake manifold casting.   Disconnect the vacuum hose from the intake manifold.   Remove the 4 bolts.

.

Remove the intake manifold MAP sensor housing.   Remove the 7 bolts.

.

Remove the fuel rail.   Remove the 4 Torx bolts.   Release the fuel injectors.   Discard the fuel injector O-ring seals.

.

Remove the fuel injector housings.   Remove the 10 Torx screws.   Release the fuel injector housings and discard the gaskets.

.

Install the fuel injector housings.   Clean the component mating faces.   Install the gaskets.   Install the Torx screws.

.

Install the fuel rail.   Clean the component mating faces.   Install fuel injector O-ring seals.   Lubricate the O-ring seals with clean engine oil.   Tighten the 4 Torx bolts to 10 Nm (7 lb.ft).

.

Install the intake manifold MAP sensor housing.   Clean the component mating faces.   Tighten the 7 bolts to 10 Nm (7 lb.ft).

.

Install the intake manifold casting.   Clean the component mating faces.   Install the 4 bolts and tighten to 10 Nm (7 lb.ft).

.

Install the NVH pad to the RH side of the intake manifold.

.

Clean the components.

.

With assistance, install the intake manifold.   Install the gaskets.   Connect the mass air flow (MAF) sensor electrical connector.   Connect the brake booster vacuum hose to the intake manifold.

.

Install the bolts.   Evenly and progressively tighten the bolts to 20 Nm (15 lb.ft).

.

Connect the fuel temperature sensor electrical connector.

.

Connect the fuel injector electrical connectors.

.

Connect the engine wiring harness to the intake manifold.

.

Install the EGR valve.   Install a new gasket.   Tighten the bolts to 10 Nm (7 lb.ft).

.

Install the engine wiring harness support bracket.   Tighten the bolts to 10 Nm (7 lb.ft).

.

Position the CMP sensor electrical connector block, to the intake manifold.

.

Connect the fuel line to the fuel rail.   Clean the component mating faces.   Position the fuel pipe into clips.

.

Install the evaporative loss valve assembly to the intake manifold bracket and connect the hose.   Clean the component mating faces.

.

Connect the crankcase vent hoses.   Clean the component mating faces.

.

Install the engine cover mounting brackets.   Tighten the nuts to 6 Nm (4 lb.ft).   Attach the wiring harness connector blocks to the brackets.

.

Install the throttle body gasket.

.

Connect the battery ground cable.

.

Connect the hood support struts.