The details to replace intake manifold are as follows :---
Intake Manifold
REMOVAL & INSTALLATION instructions are mentioned below:----
3.0L Engine
3.8L Engines
Lower Manifold
Upper Intake Manifold (Plenum)
This details will help.
Thanks.
Car repair guide?
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Intake Manifold
REMOVAL & INSTALLATION instructions are mentioned below:----
3.0L Engine
- Remove or disconnect the following:
NOTEThe lower intake manifold may be removed with the fuel injection supply manifold and fuel injectors in place as an assembly.
Negative battery cableCoolantCrankcase ventilation tube from the valve coverAir cleaner inlet and outlet tubesFuel system pressureFuel line safety clips and disconnect the fuel linesVacuum linesAll electrical wiring attached to the intake manifoldAll control cablesRadiator and heater hosesAlternator braceEGR tube and EGR valveFuel charging assemblyIgnition wiresIgnition coil packCamshaft position sensorValve coversNo. 3 intake valve pushrod
Lower intake manifold retaining bolts using a Torx® head socket. Use a soft-faced mallet to tap the manifold upward if it is hard to remove.Intake manifold
To install:
- Thoroughly clean all gasket mating surfaces on the intake manifold and cylinder head.
WARNINGWhen cleaning the cylinder head gasket surfaces, lay a clean cloth in the valve tappet area to prevent any particles from entering the oil drain-back area. - Apply a 0.25 in. (6mm) bead of silicone rubber sealant to the intersection of the cylinder block and cylinder head at the 4 corners of the intake manifold.
- Install the intake manifold gaskets, aligning the intake gasket locking tabs to provisions on the head. Install the front and rear intake manifold end seals and secure with retainers.
- Install or connect the following:
Intake manifoldIntake bolts Nos. 1, 2, 3, and 4. Tighten by hand.Remaining intake bolts and tighten all bolts in sequence to 15-22 ft. lbs. (20-30 Nm). Tighten again in sequence to 20-23 ft. lbs. (26-32 Nm).
No. 3 intake valve pushrod and rocker armValve coversCamshaft position sensorCoil pack and ignition wiresFuel charging assembly, and tighten the bolts to 71-106 inch lbs. (8-12 Nm)EGR tube and EGR valveAlternator braceRadiator and heater hosesControl cablesAll electrical wiringVacuum linesFuel lines and install the fuel line safety clipsAir cleaner inlet and outlet tubesCrankcase ventilation tube - Fill and bleed the engine cooling system.
- Connect the negative battery cable.
- Start the engine and check for leaks.
Lower Manifold
- Remove or disconnect the following:
NOTEThe lower intake manifold is sealed at each corner with sealer. To break the seal it may be necessary to pry on the front of the intake manifold with a prybar. If it is necessary, use care to prevent damage to the machined surfaces.
CoolantUpper intake manifoldWater bypass hose from the heater water outlet tubeBypass hose from the lower intake manifoldFuel system pressureElectrical wiring harnessesFuel injectors and fuel charging assemblyVacuum motor and bracket assembliesValve assembly and linkage from the IMRC lever and bushing by using a prytoolTube retaining boltsOld bushing from the leverEGR valve and adapterLower intake manifold retaining bolts
Lower intake manifold
To install:
- Thoroughly clean all gasket mating surfaces.
NOTEWhen using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set up and its sealing effectiveness may be reduced. - Install or connect the following:
New bushings into the IMRC leversApply a 3mm bead of RTV silicone sealer at each corner where the cylinder head joins the engine block
Front and rear intake manifold sealsLower intake manifold into position on the cylinder block, using new gasketsApply pipe sealant to the intake bolts and install in their original locations. Tighten in sequence to 71-106 inch lbs. (8-12 Nm).EGR valve and adapterIMRC vacuum motors, and tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm)Fuel injectors and charging assembly. Tighten retaining bolts to 71-97 inch lbs. (8-11 Nm).Water bypass tube to the lower intake manifold. Tighten the retaining bolts to 71-97 inch lbs. (8-11 Nm).Water bypass tube hose to the outlet tube and tighten the hose clamp securelyElectrical wiring harnessesVacuum lines to the IMRC motorsUpper radiator hose to water hose connection and tighten the hose clamp securelyUpper intake manifold - Fill and bleed the cooling system.
- Start the engine and check for leaks.
- Remove or disconnect the following:
NOTEKeep the intake manifold bolts in order, so they can be installed in their original positions.
Air cleaner outlet tubeAccelerator cable and speed control actuator cable at the throttle bodyAccelerator cable bracket and position it asideVacuum linesNecessary electrical harnessesCrankcase ventilation tube from the PCV valveThrottle bodyIdle air control valveIntake manifold retaining bolts, noting their positions
Upper intake manifold
To install:
- Inspect the intake gasket to ensure the seals are completely installed in the manifold groove and the seals show no signs of damage.
- Install or connect the following:
Intake manifold and tighten the bolts to 71-106 inch lbs. (8-12 Nm) in the sequence shown
Idle air control valveThrottle bodyCrankcase ventilation tube to the PCV valveElectrical harnessesVacuum linesAccelerator cable bracket and tighten the bolts to 71-106 inch lbs. (8-12 Nm)Accelerator cable and speed control actuator cable at the throttle bodyAir cleaner outlet tube
This details will help.
Thanks.
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