Intake Manifold

REMOVAL & INSTALLATION

2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable
   • Air cleaner housing and fresh air duct
   • Mass Air Flow (MAF) sensor
   • Throttle body intake hose
   • Accelerator cable and bracket
   • Intake Manifold Runner Control (IMRC) cable at the IMRC housing
   • Throttle body
   • Exhaust Gas Recirculation (EGR) valve
   • Idle Air Control (IAC) valve
   • Pressure Regulator Control (PRC) solenoid
   • Intake manifold
   • Fuel lines
   • Fuel pressure regulator vacuum line
   • Fuel supply manifold
   • IMRC housing

   To install:

   NOTE: Refer to Section 1 of this manual for the intake manifold torque sequence illustration. The illustration is located after the Torque Specification Chart.

4. Install or connect the following:
   • IMRC housing. Tighten the bolts in sequence to 72–105 inch lbs. (8–12 Nm).
   • Fuel supply manifold. Tighten the bolts to 72–105 inch lbs. (8–12 Nm).
   • Fuel pressure regulator vacuum line
   • Fuel lines
   • Intake manifold. Tighten the bolts in sequence to 72–105 inch lbs. (8–12 Nm).
   • PRC solenoid. Tighten the bolt to 45–61 inch lbs. (5–7 Nm).
   • IAC valve. Tighten the bolts to 72–105 inch lbs. (8–12 Nm).
   • EGR valve
   • Throttle body. Tighten the bolts to 72–105 inch lbs. (8–12 Nm).
   • IMRC cable
   • Accelerator cable and bracket. Tighten the bolt to 71–94 inch lbs. (8–11 Nm).
   • Throttle body intake hose
   • MAF sensor
   • Air cleaner housing and fresh air duct
   • Negative battery cable
5. Start the engine and check for leaks.

3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   • Negative battery cable
   • Fresh air duct
   • Air intake hose
   • Air cleaner assembly
   • Mass Air Flow (MAF) sensor
   • Accelerator cable
   • Cruise control cable
   • Idle Air Control (IAC) valve connector and hoses
   • Bypass air solenoid valve connector, if equipped
   • Vacuum solenoid valve connectors
   • Upper radiator hose
   • Heater hose
   • Bypass hose
   • Intake manifold vacuum lines
   • Upper intake manifold
   • Fuel lines
   • Fuel supply manifold
   • Lower intake manifold

   To install:

   NOTE: Refer to Section 1 of this manual for the intake manifold torque sequence illustration. The illustration is located after the Torque Specification Chart.

5. Install the lower intake manifold with new gaskets. Install the washers with the white paint marks facing UP. Tighten the nuts to 14–18 ft. lbs. (19–25 Nm).
6. Install or connect the following:
   • Fuel supply manifold. Tighten the nuts to 14–18 ft. lbs. (19–25 Nm).
   • Fuel lines
   • Upper intake manifold. Tighten the bolts to 70–95 inch lbs. (8–11 Nm).
   • Intake manifold vacuum lines
   • Bypass hose
   • Heater hose
   • Upper radiator hose
   • Vacuum solenoid valve connectors
   • Bypass air solenoid valve connector, if equipped
   • IAC valve connector and hoses
   • Accelerator cable
   • Cruise control cable
   • MAF sensor
   • Air cleaner assembly
   • Air intake hose
   • Fresh air duct
   • Negative battery cable
7. Fill the cooling system.
8. Start the engine and check for leaks.