To remove the intake manifold, set the ignition switch off and take out the cable from the battery's negative terminal, and slid off the plastic engine cover. Then, unscrew the vacuum line of the brake booster, and then take off both the PCV air tubes, and remove the fuel supply line from the fuel rail too. Remove the EVAP tube from the purge solenoid and place it off to the side, and label and remove several wiring connection for interference, unclipping the large wiring harness from the plastic clips on the fuel rail. Take the MAP sensor off the top of the intake manifold, then remove the EVAP purge solenoid valve from its position, and also eliminate the bracket. Loosen the intake manifold mounting bolts slowly in the opposite sequence used in tightening until they can be removed manually, they then pull up the manifold from the engine, care should be taken not to pry between the manifold and the heads as this can harm the gasket sealing surfaces. With the manifold lifted you have to look for items connected to the manifold; this can be done by use of finger and the Displacement on Demand assembly can be withdrawn at this juncture amicably avoiding the electrical lead frame. When assembling the
Cylinder Heads, block and manifold the mating surfaces should be clean; it helped to avoid damaging the surfaces while removing the remains of the previous gasket. After that, it is necessary to wipe the parts that are in contact with each other with a rag soaked in safety solvent and, if there are any fallen particles in the intake ports, use a vacuum cleaner. Remove surplus material in the bolt holes by chasing the threads with a tap of the right size, then blow clean with compressed air, if possible. Insert the new gaskets on the intake manifold so that those little tabs go on the other pads and click, then put the manifold to the block real gently. Use medium-strength thread locking compound to the bolts threading, screwing and tighten the bolts with utmost force up to the specified torque without going beyond it to avoid gasket leakages. Last of all, perform the other parts of the installation in the reverse order of removal, refill the coolant and start the engine to gently check for vacuums leaks at the joineries of intake manifold.