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Use a chiltons manual first to study the designs and specifications.
safety:1.drain all coolant. the plug is at the base of the radiator and is a plastic plug that requires a Phillips head. take care not to lose it.
2.relieve the fuel pressure by starting the engine and then pulling out the fuel fuse located in the cab. for exact location, use the diagram on the cover plate.
3.disconnect the battery and cover the terminal and the wire leading to it to prevent them from touching or bridging the space between them.
First, you must free all of the wires and cables that will be over the intake area. Then remove the spark plug cap. and the plug wirse from their plugs. keep plu#6 and its wire connected to each other, but separate the wire from the cap and lay it aside. Then start loosening hoses that are connected to the back of the plenum. they are hard to get at and I cut them, and replaced them with new ones because it was so much easier that way instead of loosening them. loosen all bolts connecting the plenum to the intake. do this in the reverse order of tightening sequence. a breaker bar will be most helpful. and feel for a sensor in the back of the plenum on its underside. also disconnect that. it will hinder movement. set the plenum to the right with most of the hoses and such still attached. then disconnect the bolt securing the intake to the frame. it is hidden under it and you have to feel for it. it takes an 8mm socket. its not too hard to get undone. but keep a magnet on hand. disconnect the coolant hose from the front side and then disconnect the fitting, requiring the removal of two bolts in the back of the manifold. disconnect the fuel line leading to the fuel bar. and try to leave the fuel bar attached to the manifold. but do disconnect the wires leading to all of the injectors. then loosen all of the manifold bolts in reverse order of tightening sequence. if the intake manifold is stuck to the heads, use a piece of wood as a buffer between your mallet and the soft aluminum. when putting it all back together, get new gaskets for everything. this is a great time to also replace your thermostat. put it in the right direction. take a picture of the thermostat in its housing when you first see it so you will be sure what direction it faces. when putting the bolts back in, use a torque bar for the right specs and always hand tighten all bolts going into any metal threads before you take a tool to them. it is tedious, but will save you from buying a new intake manifold or plenum. reinstall all as before seen and make it pretty. reconnect the fuse, and put the coolant back in. enjoy.
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