Intake Manifold: Service and Repair

REMOVAL
1. Perform fuel system pressure release procedure (before attempting any repairs). Refer to Powertrain Management for procedure.
2. Disconnect negative cable from battery.
3. Drain cooling system only if lower intake manifold is to be removed.
4. Remove air inlet resonator to throttle body hose.

Throttle Cable Attachment:

5. Remove throttle and speed control cables.

Electrical And Vacuum Connections To Throttle Body:

6. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body.
7. Remove vacuum hose harness from throttle body.
8. Remove PCV and brake booster hoses from upper intake plenum.

Ignition Coil Removal:

9. Remove ignition coil from intake plenum.

Coolant Temperature Sensor Electrical Connections:

10. Remove wiring connectors from coolant temperature sensor.
11. Remove vacuum connections from upper intake plenum vacuum connector.
12. Remove fuel hose from fuel rail.

WARNING: WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

Air Intake Plenum To Intake Manifold Attaching Bolts:

13. Remove fasteners from upper intake plenum to lower intake manifold.

Removing Air Intake Plenum:

14. Remove upper air intake plenum.

Vacuum Connections For Fuel Rail And Fuel Pressure Regulator:

15. Cover lower intake manifold with suitable cover when servicing.
16. Disconnect fuel injector wiring harness from engine wiring harness.
17. Remove fuel rail attaching bolts and lift fuel rail assembly from intake manifold.
18. Separate radiator hose from thermostat housing and heater hose from heater pipe.

Intake And Exhaust Manifolds-3.0L Engine:

19. Remove nut and washer assemblies and remove intake manifold.
20. Inspect and clean manifold. Refer to Cleaning and Inspection for procedures.

INSTALLATION
1. Position new intake manifold gaskets on cylinder head and install lower intake (cross) manifold.

Fastener Tighting Sequence For Intake (Cross) Manifold:

2. Install nuts and washers and tighten in several steps in order to 20 Nm (174 inch lbs.).
3. Make sure the injector holes are clean and all plugs have been removed.
4. Lube injector O-ring with a drop of clean engine oil to ease installation.
5. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.
6. Install the fuel rail attaching bolts and torque to 13 Nm (115 inch lbs.).
7. Install fuel supply and the vacuum crossover tube hold-down bolt. Torque to 10 Nm (95 inch lbs.).
8. Remove covering from lower intake manifold and clean surface.

Intake Plenum Tighting Sequence:

9. Place intake manifold gaskets with beaded sealant side up on lower manifold. Position upper intake plenum in place. Install attaching fasteners and tighten fasteners in several steps in sequence to 13 Nm (115 inch lbs.).
10. Connect fuel line to fuel rail. Torque hose clamps to 1 Nm (10 inch lbs.).
11. Connect vacuum harness to upper intake plenum.
12. Connect and coolant temperature sensor electrical connector to sensor.
13. Connect PCV and brake booster supply hose to upper intake plenum.
14. Connect Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) electrical connectors.
15. Connect vacuum vapor harness to throttle body.
16. Install throttle and speed control cables.
17. Install air inlet resonator hose assembly to throttle body.
18. Install radiator to thermostat housing hose and heater hose to heater pipe nipple.
19. If drained, fill cooling system.
20. Connect negative battery cable.
21. With the DRB Scan Tool use ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the Auto Shutdown (ASD) Fuel System Test. The Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.