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 Upper Radiator Hose.JPG | Hits: 2039 | Size: 86.41 KB | Posted on: 11/25/06 | Link to this image
Step 12:
Remove the 2 10mm bolts that holds the thermostat housing in place. Remove the thermostat housing, bolts, and spacers. DO NOT REMOVE THE THERMOSTAT. This is a safety just in case some dirt or debris could get dropped into the intake and down into the water jacket inside the head.
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 IAC, TPS, #7 injector harness.JPG | Hits: 1761 | Size: 75.79 KB | Posted on: 11/21/06 | Link to this image
Step 13:
Remove the Idle Air Control Valve wire harness.
Remove the Throttle Position Sensor Wire harness.
Remove the #7 Fuel injector wire harness.
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 Passenger side injector harness removed.JPG | Hits: 889 | Size: 96.52 KB | Posted on: 11/25/06 | Link to this image
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 Intake Zip Tube.JPG | Hits: 3504 | Size: 91.33 KB | Posted on: 11/21/06 | Link to this image
Step 8:
Remove the intake Zip tube by loosening the hose clamp on the throttle body and removing both the 2 hoses that enter the backside of the zip tube. These are the Idle air control valve feed hose and the crankcase ventilation tube. Remove the zip tube from the throttle body.
Next loosen the hose clamp on the zip tube and MAF sensor housing located behind the airbox. You can now remove the zip tube and set aside.
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 Water pump and alternator removed_edit.JPG | Hits: 2221 | Size: 99.16 KB | Posted on: 11/25/06 | Link to this image
Step 9,10, and 11
Remove the alternator by removing the 2 10mm bolts underneith the alternator. Set alternator aside and leave the 2 bolts WITH the alternator.
Remove the water pump by first removing the 4 13mm bolts around the waterpump. then use a Large screwdriver(or prybar) to pry the waterpump loose using the 2 tabs prived in the casting of the pump. Once pump is removed, set it aside along with the 4 bolts.
Remove the upper radiator hose clamp and hose.
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 Serpentine Belt Removal.JPG | Hits: 4054 | Size: 107.72 KB | Posted on: 11/25/06 | Link to this image
Step 5:
Insert a 1/2 nich drive breaker bar into the tensioner pulley as indicated. Rotate handle clockwise to release tension on the belt. Remove belt off of alternator pulley. Relas the breaker bar. Remove belt from accessories and set aside.
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 Battery Disconnect.JPG | Hits: 843 | Size: 94.98 KB | Posted on: 11/21/06 | Link to this image
Step 1.
Disconnect the battery. You will be removing alot of wiring and dealing with the fuel induction system.
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Step 2.
Remove the fan shroud. This requires the electric fan wires to be disconnected. There is also 2 8mm bolts to remove. one is located on the passenger side and one on the driver side of the shroud.
Note: There is a small "hook" on the bottom of the shroud that the lower coolant hose rests on. You must slide the hose off of the hook and then pull the shroud up and out.
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 Driver side Fuel injector harness 1.JPG | Hits: 1094 | Size: 101.76 KB | Posted on: 11/21/06 | Link to this image
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Step 2.
Remove the fan shroud. This requires the electric fan wires to be disconnected. There is also 2 8mm bolts to remove. one is located on the passenger side and one on the driver side of the shroud.
Note: There is a small "hook" on the bottom of the shroud that the lower coolant hose rests on. You must slide the hose off of the hook and then pull the shroud up and out.
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 Thermostatic Fan Removal.JPG | Hits: 709 | Size: 81.91 KB | Posted on: 11/25/06 | Link to this image
Step 3:
Removing the thermostatic fan will require a pulley wrench. You can get these vehicle specific but I opted to get the universoal wrench so I can use it on other vehicles. The universal wrench is a PITA to use but worth the aggravation to be able to use it on more than one type of vehicle.
Set the pulley wrench across 2 pulley bolts and then use an adjustable wrench on the fan to loosen it. You might need a few taps with a rubber mallet to break the locktite free.
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 Fan Pulley Removal.JPG | Hits: 674 | Size: 105.92 KB | Posted on: 11/21/06 | Link to this image
Step 4:
Using the pulley wrench, loosen 2 of the 10mm bolts holding the pulley to the water pump(DO NOT REMOVE). then rotate the pulley wrench onto the 2 bolts you just loosened and loosen the other 2 10mm bolts.(DO NOT REMOVE).
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 Coilpack labeling.JPG | Hits: 769 | Size: 84.67 KB | Posted on: 11/21/06 | Link to this image
Step 6:
Follow all of the spark plug wires back from each cylinder and label the coilpack locations. Also mark the top of the plug boot at the coilpack towers. We will be removing all spark plug wires at once along with all of the seperators still intact and the alternator bracket all as one unit.
After you label the plug wire locations, remove the 3 8mm bolts in the alternator bracket. Set bots aside but do not lose.
You may now unplug all spark plug wires from the spark plugs and coilpacks. DO NOT TRY TO REMOVE THE PLUG WIRE ASSEMBLY UNTIL AFTER THE NEXT STEP.
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 Linkage removed.JPG | Hits: 583 | Size: 93.28 KB | Posted on: 11/21/06 | Link to this image
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 Alternator Harness Removal.JPG | Hits: 670 | Size: 96.63 KB | Posted on: 11/21/06 | Link to this image
Step 7:
With the Alternator bracket unbolted, you now have easier access to the alternator wiring. Remove the 10mm nut and remove the wire. Replace the nut. With a VERY small screwdriver, insert it down into the other 2 harnesses located under the alternator bracket. Gently pry back on the locking clip and pull harness assemblies loose. remove all 3 harnesses and tuck them back out of the way. YOU MAY NOW CAREFULLY REMOVE THE SPARK PLUG WIRE ASSEMBLY AND SET ASIDE.
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 Broken water Pump.JPG | Hits: 722 | Size: 74.19 KB | Posted on: 11/21/06 | Link to this image
OK, so my prybar was an actual crowbar!!! I figured this pump had NEVER been removed and it was gonna be a PITA. I recomend once the pump is out an eighth inch that you use a hammer and LARGE flat screwdriver to get the pump fully removed. Alternate sides as you lightly tap the screwdriver down each side of the pump.
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 Closeup of Passenger Rear Head..JPG | Hits: 576 | Size: 96.93 KB | Posted on: 11/21/06 | Link to this image
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 Coolant hose under NPI intake.JPG | Hits: 773 | Size: 81.97 KB | Posted on: 11/21/06 | Link to this image
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 Coolant Nipple Removed.JPG | Hits: 851 | Size: 96.99 KB | Posted on: 11/21/06 | Link to this image
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 Coolant Tube and Nipple Removed.JPG | Hits: 568 | Size: 92.35 KB | Posted on: 11/21/06 | Link to this image
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 Coolant Tube Dissappears behind the head.JPG | Hits: 605 | Size: 100.37 KB | Posted on: 11/21/06 | Link to this image
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 DFPE Closeup removed.JPG | Hits: 552 | Size: 95.13 KB | Posted on: 11/21/06 | Link to this image
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 DFPE lower vacuum hose removed.JPG | Hits: 1222 | Size: 100.04 KB | Posted on: 11/21/06 | Link to this image
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 Dorman NPI Manifold Bottm.JPG | Hits: 606 | Size: 100.83 KB | Posted on: 11/21/06 | Link to this image
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 EZ-OUT #6 Used to remove coolant nipple.JPG | Hits: 523 | Size: 98.52 KB | Posted on: 11/21/06 | Link to this image
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 Fuel Line High Pressure Disconnects.JPG | Hits: 1378 | Size: 96.06 KB | Posted on: 11/21/06 | Link to this image
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 Fuel Rails Still connected.JPG | Hits: 674 | Size: 109.42 KB | Posted on: 11/21/06 | Link to this image
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 Head Ports Closeup.JPG | Hits: 565 | Size: 80.53 KB | Posted on: 11/21/06 | Link to this image
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 Inside My very own ported intake plenum.JPG | Hits: 552 | Size: 90.51 KB | Posted on: 11/21/06 | Link to this image
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 Intake Plenum Removed with IAC, TB and Pressure feedback thingy.JPG | Hits: 663 | Size: 93.85 KB | Posted on: 11/21/06 | Link to this image
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 Intake ready to Pull off.JPG | Hits: 598 | Size: 110.14 KB | Posted on: 11/21/06 | Link to this image
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 NPI Intake Removed 1.JPG | Hits: 633 | Size: 120.21 KB | Posted on: 11/21/06 | Link to this image
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 NPI Intake Removed 2.JPG | Hits: 646 | Size: 98.61 KB | Posted on: 11/21/06 | Link to this image
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 Old Coolant Tube.JPG | Hits: 573 | Size: 108.26 KB | Posted on: 11/25/06 | Link to this image
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 PI Intake gasket tabs need removal.JPG | Hits: 813 | Size: 53.18 KB | Posted on: 11/25/06 | Link to this image
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 PI Intake Temp Sensor Tapped and Installed.JPG | Hits: 851 | Size: 105.82 KB | Posted on: 11/25/06 | Link to this image
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 Upper Intake elbow removed.JPG | Hits: 607 | Size: 104.95 KB | Posted on: 11/25/06 | Link to this image
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 Upper Plenum Top View 1.JPG | Hits: 710 | Size: 98.79 KB | Posted on: 11/25/06 | Link to this image
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 Upper Plenum Top View 2.JPG | Hits: 642 | Size: 97.42 KB | Posted on: 11/25/06 | Link to this image
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PI INTAKE SWAP(HOT!!!!)
