Properly relieve the fuel system pressure.
Disconnect the negative battery cable and drain the cooling system.
Remove the intake manifold with the throttle body.
Disconnect the coil wires, sending unit wire, heater hoses and bypass hose.
Remove the closed ventilation system, evaporation control system and cylinder head cover(s).
Clean all gasket mating surfaces.
Install the valve cover with a new gasket. Tighten the valve cover bolts to 105 inch lbs. (12 Nm). Install the exhaust manifold crossover pipe. Tighten the bolts to 20 ft. Lbs. (27 Nm) and the nuts to 15 ft. Lbs. (20 Nm).
Install the closed ventilation system and the evaporation control system.
Reconnect the coil wires, sending unit wire, heater hoses and bypass hose.
Ensure all wiring connections, cables, hoses, vacuum and fuel lines have been reattached.
Refill the cooling system to the correct level.
Reconnect the negative battery cable. Start the engine and check for leaks.
INTAKE MANIFOLD REMOVAL
Drain the cooling system.
Relieve the fuel system pressure.
Remove or disconnect the following:
Negative battery cable
Air cleaner and tube
Idle Air Control (IAC) valve connector
Cruise control cable
Make up air hose support clip from the throttle cable bracket
Automatic Idle Speed (IAS) and Throttle Position (TP) sensor connectors
Manifold Absolute Pressure (MAP) sensor connector
Exhaust Gas Recirculation (EGR) transducer connector, if equipped
EGR tube, if equipped
Vapor purge vacuum hose from the throttle body
Positive Crankcase Ventilation (PCV) hose
Power steering reservoir bolts and loosen the nut, lift the reservoir up to disengage the lower mount from the stud and position aside with the lines still attached.
Brake booster and leak detection pump hoses
Upper intake manifold
Ignition coil and bracket
Heater supply hose and Engine Coolant temperature (ECT) sensor
Fuel injector harness connectors
Fuel supply manifold
Upper radiator hose
Lower intake manifold
Thursday, May 20th, 2010 AT 9:31 PM