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For 1990-2009 cars only

Intake Manifold Replacement 5.3L

Removal Procedure

  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Note: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.

  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement.
  4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

  5. Object Number: 898468  Size: SH
  6. Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
  7. Remove the harness clip (1) from the cylinder head.

  8. Object Number: 1204792  Size: SH
  9. Disconnect the electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor.
  10. Remove the harness clips from the fuel rail.

  11. Object Number: 1209783  Size: SH
  12. Perform the following steps in order to disconnect the fuel injector electrical connectors.
  13. 8.1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
    8.2. Pull the connector position assurance (CPA) retainer (2) on the connector up one click.
    8.3. Push the tab (1) on the connector in.
    8.4. Disconnect the fuel injector electrical connector.
    8.5. Repeat the steps for each injector electrical connector.

    Object Number: 1618062  Size: SH
  14. Disconnect the following electrical connectors:
  15. • Evaporative emission (EVAP) purge solenoid (3)
    • Throttle body harness (5)
    • Manifold absolute pressure (MAP) sensor (2)
    • Main coil (1)
    • Generator (4)
  16. Remove the electrical harness clips from the fuel rail.

  17. Object Number: 1485981  Size: SH
  18. Remove the positive crankcase ventilation (PCV) hose.

  19. Object Number: 898349  Size: SH
  20. Remove the heater water shutoff valve actuator inlet hose from the intake manifold.

  21. Object Number: 1485982  Size: SH
  22. Remove the EVAP purge solenoid vent tubes (1, 2). Refer to Plastic Collar Quick Connect Fitting Service.

  23. Object Number: 1366114  Size: SH
  24. Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service.

  25. Object Number: 898352  Size: SH
  26. Remove the vacuum brake booster hose from the rear of the intake manifold.

  27. Object Number: 899740  Size: SH
  28. Remove the upper engine wire harness retainer nut (1).
  29. Reposition the upper engine wire harness aside.

  30. Object Number: 1618083  Size: SH
  31. Remove the intake manifold bolts.
  32. Remove the intake manifold.

  33. Object Number: 492770  Size: SH
  34. Remove the intake manifold gaskets (1) from the intake manifold.
  35. Discard the old intake manifold gaskets.
  36. If necessary, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.

Installation Procedure


    Object Number: 492770  Size: SH
  1. Install NEW intake manifold gaskets (1) to the intake manifold.

  2. Object Number: 1618083  Size: SH
  3. Install the intake manifold.
  4. Apply a 5 mm (0.2 in) bead of threadlock to the threads of the intake manifold bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
  5. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 63222  Size: SH
  6. Install the intake manifold bolts.
  7. 4.1. Tighten the bolts a first pass in sequence to 5 N·m (44 lb in).
    4.2. Tighten the bolts a final pass in sequence to 10 N·m (89 lb in).

    Object Number: 899740  Size: SH
  8. Route the electrical harness into position over the engine.
  9. Install the engine harness bracket nut (1) and tighten to 10 N·m (89 lb in).

  10. Object Number: 898352  Size: SH
  11. Install the vacuum brake booster hose to the rear of the intake manifold.

  12. Object Number: 1366114  Size: SH
  13. Connect the fuel feed pipe (3) to the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service.

  14. Object Number: 1485982  Size: SH
  15. Install the EVAP purge solenoid vent tubes (1, 2). Refer to Plastic Collar Quick Connect Fitting Service.

  16. Object Number: 898349  Size: SH
  17. Install the heater water shutoff valve actuator inlet hose to the intake manifold.

  18. Object Number: 1485981  Size: SH
  19. Install the PCV hose.
  20. Connect the electrical harness clips to the fuel rail.

  21. Object Number: 1618062  Size: SH
  22. Connect the following electrical connectors:
  23. • EVAP purge solenoid (3)
    • Throttle body harness (5)
    • MAP sensor (2)
    • Main coil (1)
    • Generator (4)

    Object Number: 1209783  Size: SH
  24. Perform the following steps in order to connect the fuel injector electrical connectors.
  25. 14.1. Install the connectors to their corresponding injectors to ensure correct reassembly.
    14.2. Connect the fuel injector electrical connector.
    14.3. Push the CPA retainer (2) on the connector in one click.
    14.4. Repeat the steps for each injector electrical connector.
  26. Install the electrical harness clips to the fuel rail.

  27. Object Number: 898468  Size: SH
  28. Connect the A/C compressor pressure switch electrical connector (2).
  29. Install the harness clip (1) to the cylinder head.

  30. Object Number: 1204792  Size: SH
  31. Connect the MAF/IAT sensor electrical connector (1).
  32. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement.
  33. Install the fuel fill cap.
  34. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  35. Use the following procedure in order to inspect for leaks:
  36. 22.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    22.2. Turn the ignition OFF for 10 seconds.
    22.3. Turn the ignition ON, with the engine OFF.
    22.4. Inspect for fuel leaks.

Intake Manifold Replacement 6.0L

Removal Procedure

Note: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly.


    Object Number: 1742620  Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  3. Disconnect the engine wiring harness electrical connector (3) from the air conditioning (A/C) compressor pressure switch.

  4. Object Number: 1204792  Size: SH
  5. Disconnect the engine harness wiring harness electrical connector (1) from the mass air flow (MAF) intake air temperature (IAT) sensor.

  6. Object Number: 1742621  Size: SH
  7. Disconnect the engine wiring harness electrical connector (1) from the electronic throttle control (ETC).
  8. Remove the right side connector position assurance (CPA) retainer (4) from the engine wiring harness main ignition coil electrical connector.
  9. Disconnect the right side engine wiring harness electrical connector (3) from the main ignition coil electrical connector.
  10. Disconnect the right side engine wiring harness electrical connectors (2) from the fuel injectors.

  11. Object Number: 1209783  Size: SH
  12. Perform the following steps in order to disconnect the fuel injector electrical connectors:
  13. 9.1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
    9.2. Pull the CPA retainer (2) on the connector up one click.
    9.3. Push the tab (1) on the connector in.
    9.4. Disconnect the fuel injector electrical connector.
    9.5. Repeat the steps for each injector electrical connector.

    Object Number: 1742624  Size: SH
  14. Remove the left side CPA retainer (3) from the engine wiring harness main ignition coil electrical connector.
  15. Disconnect the left side engine wiring harness electrical connector (2) from the main ignition coil electrical connector.
  16. Disconnect the left side engine wiring harness electrical connectors (1) from the fuel injectors.

  17. Object Number: 1209783  Size: SH
  18. Perform the following steps in order to disconnect the fuel injector electrical connectors:
  19. 13.1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
    13.2. Pull the CPA retainer (2) on the connector up one click.
    13.3. Push the tab (1) on the connector in.
    13.4. Disconnect the fuel injector electrical connector.
    13.5. Repeat the steps for each injector electrical connector.

    Object Number: 1742623  Size: SH
  20. Disconnect the engine wiring harness electrical connector from the generator.

  21. Object Number: 1742627  Size: SH
  22. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
  23. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid valve.

  24. Object Number: 1485981  Size: SH
  25. Remove the positive crankcase ventilation (PCV) hose.

  26. Object Number: 1485982  Size: SH
  27. Remove the EVAP purge solenoid vent tubes (1, 2). Refer to Plastic Collar Quick Connect Fitting Service.

  28. Object Number: 1366114  Size: SH
  29. Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service.
  30. Reposition the vacuum brake booster hose clamp at the brake booster.
  31. Remove the vacuum brake booster hose from the brake booster.

  32. Object Number: 1742671  Size: SH
  33. Remove the engine wire harness retainer nut.
  34. Reposition the upper engine wire harness aside.

  35. Object Number: 899619  Size: SH
  36. Remove the drive belt. Refer to Drive Belt Replacement - Accessory.
  37. Remove the right generator bolt.
  38. Loosen the left generator bolt and reposition the generator to the left.

  39. Object Number: 1403311  Size: SH
  40. Remove the intake manifold bolts (512).
  41. Remove the intake manifold.

  42. Object Number: 1277097  Size: SH
  43. Remove the intake manifold gaskets (514) from the intake manifold.
  44. Discard the old intake manifold gaskets.
  45. If necessary, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.

Installation Procedure


    Object Number: 1277097  Size: SH
  1. Install NEW intake manifold gaskets (514) to the intake manifold.

  2. Object Number: 1403311  Size: SH
  3. Install the intake manifold.
  4. Apply a 5 mm (0.2 in) bead threadlock to the threads of the intake manifold bolts (512). Refer to Adhesives, Fluids, Lubricants, and Sealers.
  5. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 63222  Size: SH
  6. Install the intake manifold bolts.
  7. Tighten

    1. Tighten the bolts a first pass in sequence to 5 N·m (44 lb in).
    2. Tighten the bolts a final pass in sequence to 10 N·m (89 lb in).

    Object Number: 899619  Size: SH
  8. Position the generator and install the right generator bolt.
  9. Tighten the left generator bolt.
  10. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  11. Install the drive belt. Refer to Drive Belt Replacement - Accessory.

  12. Object Number: 1742671  Size: SH
  13. Route the electrical harness into position over the engine.
  14. Install the engine harness bracket nut.
  15. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 1366114  Size: SH
  16. Install the vacuum brake booster hose to the brake booster.
  17. Position the vacuum brake booster hose clamp at the brake booster.
  18. Connect the fuel feed pipe (3) to the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service.

  19. Object Number: 1485982  Size: SH
  20. Install the EVAP purge solenoid vent tubes (1, 2). Refer to Plastic Collar Quick Connect Fitting Service.

  21. Object Number: 1485981  Size: SH
  22. Install the PCV hose.

  23. Object Number: 1742627  Size: SH
  24. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
  25. Connect the engine wiring harness electrical connector (2) to the EVAP canister purge solenoid valve.

  26. Object Number: 1742623  Size: SH
  27. Connect the engine wiring harness electrical connector to the generator.

  28. Object Number: 1742624  Size: SH
  29. Connect the left side engine wiring harness electrical connector (2) to the main ignition coil electrical connector.
  30. Install the left side CPA retainer (3) to the engine wiring harness main ignition coil electrical connector.
  31. Connect the left side engine wiring harness electrical connectors (1) to the fuel injectors.

  32. Object Number: 1209783  Size: SH
  33. Perform the following steps in order to connect the fuel injector electrical connectors:
  34. 21.1. Install the connectors to their corresponding injectors to ensure correct reassembly.
    21.2. Connect the fuel injector electrical connector.
    21.3. Push the CPA retainer (2) on the connector in one click.
    21.4. Repeat the steps for each injector electrical connector.

    Object Number: 1742621  Size: SH
  35. Connect the engine wiring harness electrical connector (1) to the ETC.
  36. Connect the right side engine wiring harness electrical connector (3) to the main ignition coil electrical connector.
  37. Install the right side CPA retainer (4) to the engine wiring harness main ignition coil electrical connector.
  38. Connect the right side engine wiring harness electrical connectors (2) to the fuel injectors.

  39. Object Number: 1209783  Size: SH
  40. Perform the following steps in order to connect the fuel injector electrical connectors:
  41. 26.1. Install the connectors to their corresponding injectors to ensure correct reassembly.
    26.2. Connect the fuel injector electrical connector.
    26.3. Push the CPA retainer (2) on the connector in one click.
    26.4. Repeat the steps for each injector electrical connector.

    Object Number: 1204792  Size: SH
  42. Connect the engine harness wiring harness electrical connector (1) to the MAF/IAT sensor.

  43. Object Number: 1742620  Size: SH
  44. Connect the engine wiring harness electrical connector (3) to the A/C compressor pressure switch.
  45. Install the fuel fill cap.
  46. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  47. Use the following procedure in order to inspect for leaks:
  48. 31.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    31.2. Turn the ignition OFF for 10 seconds.
    31.3. Turn the ignition ON, with the engine OFF.
    31.4. Inspect for fuel leaks.