Intake Manifold

Removal & Installation

CAUTION
Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.

Upper Intake Manifold

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.
4. Remove the bolt and snow shield.
5. Disconnect the accelerator cable, speed control cable, and the return spring.
6. Disconnect the accelerator cable and speed control cable from the accelerator bracket.
7. Disconnect the throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
8. Disconnect the two vacuum hoses.
9. Detach the 42-pin wiring harness retainer from the stud bolt.
10. Remove the nut and stud bolt then place the 42-pin wiring harness and bracket aside.
11. Remove the dipstick tube bracket nut and the upper intake manifold support bracket stud bolt.
12. Disconnect the brake booster vacuum hose and the positive crankcase ventilation (PCV) valve tube.
13. Remove the bolts, the stud bolt, and the upper intake manifold. Remove and discard the gaskets. Clean and inspect all gasket sealing surfaces.

To Install:

1. Clean all mating surfaces.
2. Install new upper intake manifold gaskets (when required).
3. Install the upper intake manifold and bolts.
4. Tighten the upper intake manifold bolts starting from the center and working out alternating front to back.
   • Torque the upper manifold bolts to 89 in-lb (10 Nm).
5. Connect the PCV valve tube and the brake booster vacuum hose.
6. Install the upper intake manifold support bracket stud bolt and the dipstick tube bracket nut.
   • Torque the upper intake manifold support bracket stud bolt to 89 in-lb (10 Nm)
   • Torque the dipstick tube bracket nut to 13 ft-lb (18 Nm).
7. Position the 42-pin connector bracket in place then reconnect and tighten the retaining bolt securely.
8. Connect the vacuum hoses.
9. Connect the TP sensor and IAC valve electrical connectors.
10. Insert and seat the accelerator cable and speed control cable.
11. Install the snow shield and bolt.
12. Install the air cleaner outlet pipe.
13. Connect the battery ground cable.
14. Start the vehicle and check for leaks, repair if necessary.

Lower Intake Manifold

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.
3. Drain the engine cooling system.
4. Remove both valve covers.
5. Disconnect the upper radiator hose, heater hose, and coolant bypass hose.
6. Disconnect the engine coolant temperature (ECT) sensor and coolant temperature sender electrical connectors.
7. Disconnect the crankshaft position (CKP) sensor and detach the wiring from the stud bolt.
8. Disconnect the fuel injector electrical connectors and position the engine control wiring aside.
9. Release the fuel pressure and disconnect the fuel tube.
10. Loosen all the rocker arm bolts.

    NOTE: Identify the location of each pushrod before removing them. Each pushrod should be installed in its original location to prevent wearing prematurely.

11. Remove the pushrods.
12. Remove the bolts from the lower intake manifold.

    NOTE: Gently loosen the intake manifold to separate the silicone sealant from the cylinder block.

13. Remove the lower intake manifold.
14. Remove and discard the intake manifold gaskets and end seals.

To Install:

1. Clean and inspect all the sealing surfaces.

   NOTE: If the lower intake manifold is not installed within four minutes, remove the sealant and reapply.

2. Install new intake manifold gaskets and seals.
   • Apply a bead of silicone gasket sealant at the four cylinder block-to-cylinder head seams.
   • Position the intake manifold gaskets.
   • Position the intake manifold front and rear seals.
3. Position the lower intake manifold.
4. Install the bolts and tighten in the sequence shown.
   • Torque to 21 ft-lb (29 Nm).

   Tighten the lower manifold bolts in the sequence shown-3.0L engine

5. Install the pushrods.
6. Tighten the rocker arms.
   • Torque to 24 ft-lb (32 Nm).
7. Connect the fuel tube.
8. Connect the fuel injector electrical connectors.
9. Connect the crankshaft position (CKP) sensor and attach the wiring from the stud bolt.
10. Connect the engine coolant temperature (ECT) sensor and coolant temperature sender electrical connectors.
11. Connect the upper radiator hose, heater hose, and coolant bypass hose.
12. Install both valve covers.
13. Fill and bleed the engine cooling system.
14. Connect the negative battery cable.
15. Start the engine. Check for any leaks and repair them as necessary.