Upper Intake Manifold
INTAKE MANIFOLD - UPPER 3.8LREMOVAL - 3.8L
1. Disconnect battery negative cable.
2. Disconnect air inlet sensor electrical connector.
3. Remove air inlet resonator to throttle body hose assembly.
4. Remove throttle and speed control cables.
5. Disconnect make-up air hose support clip from throttle cable bracket.
6. Disconnect the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body.
7. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
8. Disconnect the EGR transducer vacuum hose from bottom of upper intake manifold (Fig. 129).
9. Remove the EGR tube (Fig. 129).
10. Disconnect the vapor purge vacuum hose from throttle body.
11. Disconnect the PCV hose (Fig. 130).
12. Remove the power steering reservoir attaching bolts and loosen the nut only (Fig. 131). Lift reservoir up to disengage lower mount from stud. Set reservoir aside. Do not disconnect hose.
13. Disconnect the brake booster and Leak Detection Pump (LDP) hoses from intake manifold (Fig. 132).
14. Remove intake manifold bolts and remove the manifold (Fig. 133).
15. Cover the lower intake manifold with a suitable cover when servicing.
16. Clean and inspect the upper intake manifold.
CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.
INSPECTION
Check manifold for:
- Damage and cracks.
- Mounting surface distortion by using a straightedge and thickness gauge.
INSTALLATION - 3.8L
1. If the following components were removed from manifold, install and tighten to specifications:
- MAP sensor - 3.4 Nm (30 in. lbs.)
- Throttle cable bracket - 12 Nm (105 in. lbs.)
2. Remove covering on lower intake manifold and clean surfaces.
3. Position the new intake manifold gasket on lower manifold.
4. Position upper manifold on lower manifold (Fig. 133). Install and tighten bolts to 12 Nm (105 in. lbs.) following torque sequence in (Fig. 134).
5. Connect the MAP sensor electrical connector.
6. Connect the brake booster and LDP vacuum hose to intake manifold (Fig. 132).
7. Connect the PCV hose (Fig. 130).
8. Install the power steering reservoir (Fig. 131) and torque fasteners to 12 Nm (105 in. lbs.).
9. Connect the EGR transducer vacuum hose.
10. Using new gaskets, install the EGR tube (Fig. 129) and torque bolts to 12 Nm (105 in. lbs.).
11. Install throttle and speed control cables.
12. Attach make up air hose clip into the hole in the throttle cable bracket.
13. Connect the vapor purge vacuum hose to throttle body.
14. Connect the wiring connectors to the Throttle Position Sensor (TPS) and Automatic Idle Speed (AIS) motor.
15. Install air cleaner and air inlet hose assembly.
16. Connect the inlet air sensor electrical connector.
17. Connect battery negative cable.