Intake Manifold Replacement Upper VIN K

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
4. Disconnect the spark plug wires from the right side of the engine. Set the wires aside.
5. Remove the manifold vacuum source.
6. Depressurize the fuel lines. Refer to Fuel Pressure Relief in Engine Controls - 3.8L.
7. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.8L.
8. Remove the EGR heat shield.
9. Remove the cable bracket to the cylinder head mounting bolt.
10. Remove the accelerator cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.8L.
11. Remove the throttle body support bracket.

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.




12. Remove the upper intake manifold bolts.
13. Remove the upper intake manifold.
14. Remove the upper intake manifold gasket.

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.




1. Install the upper intake manifold gasket.
2. Remove the upper intake manifold.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the upper intake manifold bolts.

Tighten
Tighten the bolts in sequence to 10 N·m (89 lb in).

4. Install the throttle body support bracket.
5. Install the accelerator cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.8L.
6. Install the cable bracket to the cylinder head mounting bolt.
7. Install the EGR heat shield.
8. Install the fuel rail. Refer Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.8L.
9. Install the manifold vacuum source.
10. Connect the spark plug wire(s) to the right side of the engine.
11. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
12. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
13. Connect the negative battery cable.

Intake Manifold Replacement Lower VIN K

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to Intake Manifold Replacement .
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the upper radiator hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
5. Remove the generator. Refer to Generator Replacement in Engine Electrical.
6. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
7. Remove the EGR valve outlet pipe.



8. Remove the lower intake manifold bolts.
9. Remove the lower intake manifold.

Important: In order to complete the installation, observe the following assembly tips:

1. Install the lower intake manifold.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the lower intake manifold bolts.

Tighten
Tighten the bolts in sequence to 15 N·m (11 lb ft).

3. Connect the negative battery cable.
4. Install the EGR valve outlet pipe.
5. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
6. Install the generator. Refer to Generator Replacement in Engine Electrical.
7. Install the upper radiator hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
8. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
9. Install the upper intake manifold. Refer to Intake Manifold Replacement .
10. Connect the negative battery cable.