Intake Manifold

REMOVAL & INSTALLATION

Upper

2.3L AND 2.5L ENGINES

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Intake Air Temperature (IAT) sensor
   • Air cleaner outlet tube
   • Accelerator control splash shield
   • Engine control sensor wiring from the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve
   • Accelerator cable and speed control cable, if equipped
   • Accelerator cable bracket
   • Crankcase vent hose from the valve cover
   • Vacuum hoses from the intake manifold vacuum tee
   • Heater hose from the intake manifold
   • Exhaust Gas Recirculation (EGR) tube
   • EGR valve
   • Upper intake manifold and discard the gasket

   To install:

3. Install a new upper intake manifold gasket.

   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 the upper intake manifold. Torque the bolts in sequence as follows:
   1. Step 1: 89 inch lbs. (10 Nm).
   2. Step 2: 28 ft. lbs. (38 Nm).
5. Install or connect the following:
   • EGR valve. Torque the bolts to 22 ft. lbs. (30 Nm).
   • EGR valve tube. Torque the bolts to 34 ft. lbs. (47 Nm).
   • Heater hoses to the intake manifold
   • Vacuum hoses to the tee
   • Crankcase vent hose to the valve cover
   • Accelerator cable bracket. Torque the bolts to 20 ft. lbs. (28 Nm).
   • Accelerator cable and speed control cable, if equipped
   • IAC valve and TP sensor electrical connectors
   • Air cleaner outlet tube
   • IAT sensor
   • Negative battery cable
6. Start the engine and check for leaks, repair if necessary.

3.0L ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Intake Air Temperature (IAT) sensor
   • Air cleaner outlet tube
   • Accelerator control splash shield
   • Accelerator cable and speed control cable, if equipped
   • Engine control sensor wiring from the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve and Exhaust Gas Recirculation (EGR) transducer
   • EGR tube from the valve
   • EGR vacuum lines
   • 42 pin connector bracket
   • Throttle body and gasket
   • Ignition coil and move it aside
   • Evaporative Emissions (EVAP) hose
   • Upper intake manifold bolts and discard them
   • Crankcase vent hose
   • Upper intake manifold and discard the gasket

   To install:

3. Clean all mating surfaces.
4. Install or connect the following:
   • New upper intake manifold
   • Intake manifold
   • Crankcase vent hose

   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. Torque the upper intake manifold bolts in sequence as follows:
   1. Step 1: 15 ft. lbs. (20 Nm).
   2. Step 2: 18 ft. lbs. (25 Nm).
6. Install or connect the following:
   • EVAP hose
   • EGR tube
   • EGR transducer. Torque the bolts to 89 inch lbs. (10 Nm).
   • Ignition coil. Torque the bolts to 15 ft. lbs. (20 Nm).
   • New gasket and throttle body. Torque the bolts to 22 ft. lbs. (30 Nm).
   • 42 pin connector
   • EGR vacuum lines
   • EGR transducer, IAC valve and TP sensor electrical connectors
   • Accelerartor cable and speed control, if equipped
   • Accelerator cable splash shield
   • Air cleaner outlet tube
   • IAT sensor
   • Negative battery cable
7. Start the vehicle and check for leaks, repair if necessary.

4.0L OHV ENGINE

The intake manifold is a 4-piece assembly, consisting of the upper intake manifold, the throttle body, the fuel supply manifold, and the lower intake manifold.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Air cleaner outlet tube
   • Accelerator cable splash shield
   • Spark plug wires from the ignition coil
   • Ignition coil and radio interference capacitor electrical connectors
   • Throttle Position (TP) sensor electrical connector
   • Idle Air Control (IAC) valve electrical connector
   • Brake booster vacuum hose
   • Positive Crankcase Ventilation (PCV) hose
   • Canister purge line from the throttle body
   • Fuel line bracket
   • Upper intake manifold and discard the gasket

   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.

3. Install or connect the following:
   • New gasket and the upper manifold. Torque the nuts to 18 ft. lbs. (25 Nm).
   • Fuel line bracket
   • Canister purge line to the throttle body
   • Brake booster vacuum hose
   • IAC valve electrical connector
   • TP sensor electrical connector
   • Ingition coil and radio interference capacitor electrical connectors
   • Spark plug wires to the proper spark plug
   • Accelerator cable and speed control cable, if equipped
   • Accelerator cable splash shield
   • Air cleaner outlet tube
   • Negative battery cable
4. Start the vehicle and check for leaks, repair if necessary.