16. Next is to remove a lot of hoses and pipes from the throttle body. Take the upper water hose off from both ends. Be careful with the radiator side b/c it’s a plastic fitting and breaking that would mean new radiator time. The red arrows are the coolant filled hoses. Use a rag when disconnecting these; they will be probably full of coolant. The blue arrows are electric connectors. There is a plastic fitting on one hose for a wire. Use a flathead to disconnect the fitting. The green arrows are the vacuum tubes and the aqua arrow is an air tube. Disconnect all hoses, connectors and pipes from the throttle assembly.
Part 3: Manifold Rear
17. Now we are going to move to the rear of the engine and really break our backs. This is why we raised the hood to its vertical position. First off, we have to remove the vacuum solenoid assembly. This is a bracket of 3 cylindrical tubes with a bunch of vacuum hoses sticking out of the sides. First, disconnect the 2 electrical connectors mounted on the bracket. Next, disconnect AND LABEL all vacuum hoses. 2 go to the intake air bypass diaphrams located on the back of the manifold, 3 go to the ones that we disconnected back when the injectors where removed, 1 goes to the control box, and 2 on the right side go somewhere not that important. Anyway, make sure these all get labeled b/c its impossible to remember where they all go. Last, remove the 2 bolts holding the bracket in place. Remove the bracket and all the attached vacuum tubes.
18. Now that the solenoids are removed, disconnect the wire harness. There are 2 bolts holding it to the manifold. Now the harness should be pretty free to move around, now you can take the last 2 bolts off to remove the mounting bracket which held the harness and solenoid valves. Also, remove the brake booster vacuum hose that connects to the back of the manifold.
19. Now we can remove the EGR valve. There are 2 nuts holding the valve on the exhaust manifold, a vacuum pipe and the electric connector. Take that off and clean out the inside really good. Also, scrape off any of the old gasket remnants and clean the both surfaces real nice.
20. The EGR pipe should be pretty clear now. We can remove the 2 bolts on the exhaust side, and the 2 nuts on the intake side to remove the pipe. It will be pretty gunked up inside, but that’s only the beginning!
