Intake Manifold Replacement 5.3L
Removal Procedure
- Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
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.
- Remove the air cleaner outlet duct. Refer to
Air Cleaner Resonator Outlet Duct Replacement.
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief.
- Disconnect the air conditioning (A/C) compressor pressure switch electrical connector (2).
- Remove the harness clip (1) from the cylinder head.
- Disconnect the electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor.
- Remove the harness clips from the fuel rail.
- Perform the following steps in order to disconnect the fuel injector electrical connectors.
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. |
- Disconnect the following electrical connectors:
• | Evaporative emission (EVAP) purge solenoid (3) |
• | Throttle body harness (5) |
• | Manifold absolute pressure (MAP) sensor (2) |
- Remove the electrical harness clips from the fuel rail.
- Remove the positive crankcase ventilation (PCV) hose.
- Remove the heater water shutoff valve actuator inlet hose from the intake manifold.
- Remove the EVAP purge solenoid vent tubes (1, 2). Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to
Metal Collar Quick Connect Fitting Service.
- Remove the vacuum brake booster hose from the rear of the intake manifold.
- Remove the upper engine wire harness retainer nut (1).
- Reposition the upper engine wire harness aside.
- Remove the intake manifold bolts.
- Remove the intake manifold.
- Remove the intake manifold gaskets (1) from the intake manifold.
- Discard the old intake manifold gaskets.
- If necessary, clean and inspect the intake manifold. Refer to
Intake Manifold Cleaning and Inspection.
Installation Procedure
- Install NEW intake manifold gaskets (1) to the intake manifold.
- Install the intake manifold.
- 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.
Caution: Refer to Fastener Caution in the Preface section.
- Install the intake manifold bolts.
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). |
- Route the electrical harness into position over the engine.
- Install the engine harness bracket nut (1) and tighten to
10 N·m (89 lb in).
- Install the vacuum brake booster hose to the rear of the intake manifold.
- Connect the fuel feed pipe (3) to the fuel rail (2). Refer to
Metal Collar Quick Connect Fitting Service.
- Install the EVAP purge solenoid vent tubes (1, 2). Refer to
Plastic Collar Quick Connect Fitting Service.
- Install the heater water shutoff valve actuator inlet hose to the intake manifold.
- Install the PCV hose.
- Connect the electrical harness clips to the fuel rail.
- Connect the following electrical connectors:
• | EVAP purge solenoid (3) |
• | Throttle body harness (5) |
- Perform the following steps in order to connect the fuel injector electrical connectors.
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. |
- Install the electrical harness clips to the fuel rail.
- Connect the A/C compressor pressure switch electrical connector (2).
- Install the harness clip (1) to the cylinder head.
- Connect the MAF/IAT sensor electrical connector (1).
- Install the air cleaner outlet duct. Refer to
Air Cleaner Resonator Outlet Duct Replacement.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Use the following procedure in order to inspect for leaks:
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.
- Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief.
- Disconnect the engine wiring harness electrical connector (3) from the air conditioning (A/C) compressor pressure switch.
- Disconnect the engine harness wiring harness electrical connector (1) from the mass air flow (MAF) intake air temperature (IAT) sensor.
- Disconnect the engine wiring harness electrical connector (1) from the electronic throttle control (ETC).
- Remove the right side connector position assurance (CPA) retainer (4) from the engine wiring harness main ignition coil electrical connector.
- Disconnect the right side engine wiring harness electrical connector (3) from the main ignition coil electrical connector.
- Disconnect the right side engine wiring harness electrical connectors (2) from the fuel injectors.
- Perform the following steps in order to disconnect the fuel injector electrical connectors:
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. |
- Remove the left side CPA retainer (3) from the engine wiring harness main ignition coil electrical connector.
- Disconnect the left side engine wiring harness electrical connector (2) from the main ignition coil electrical connector.
- Disconnect the left side engine wiring harness electrical connectors (1) from the fuel injectors.
- Perform the following steps in order to disconnect the fuel injector electrical connectors:
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. |
- Disconnect the engine wiring harness electrical connector from the generator.
- Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
- Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) canister purge solenoid valve.
- Remove the positive crankcase ventilation (PCV) hose.
- Remove the EVAP purge solenoid vent tubes (1, 2). Refer to
Plastic Collar Quick Connect Fitting Service.
- Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to
Metal Collar Quick Connect Fitting Service.
- Reposition the vacuum brake booster hose clamp at the brake booster.
- Remove the vacuum brake booster hose from the brake booster.
- Remove the engine wire harness retainer nut.
- Reposition the upper engine wire harness aside.
- Remove the drive belt. Refer to
Drive Belt Replacement - Accessory.
- Remove the right generator bolt.
- Loosen the left generator bolt and reposition the generator to the left.
- Remove the intake manifold bolts (512).
- Remove the intake manifold.
- Remove the intake manifold gaskets (514) from the intake manifold.
- Discard the old intake manifold gaskets.
- If necessary, clean and inspect the intake manifold. Refer to
Intake Manifold Cleaning and Inspection.
Installation Procedure
- Install NEW intake manifold gaskets (514) to the intake manifold.
- Install the intake manifold.
- 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.
Caution: Refer to Fastener Caution in the Preface section.
- Install the intake manifold bolts.
Tighten
- Tighten the bolts a first pass in sequence to 5 N·m (44 lb in).
- Tighten the bolts a final pass in sequence to 10 N·m (89 lb in).
- Position the generator and install the right generator bolt.
- Tighten the left generator bolt.
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Install the drive belt. Refer to
Drive Belt Replacement - Accessory.
- Route the electrical harness into position over the engine.
- Install the engine harness bracket nut.
Tighten
Tighten the nut to 10 N·m (89 lb in).
- Install the vacuum brake booster hose to the brake booster.
- Position the vacuum brake booster hose clamp at the brake booster.
- Connect the fuel feed pipe (3) to the fuel rail (2). Refer to
Metal Collar Quick Connect Fitting Service.
- Install the EVAP purge solenoid vent tubes (1, 2). Refer to
Plastic Collar Quick Connect Fitting Service.
- Install the PCV hose.
- Connect the engine wiring harness electrical connector (1) to the MAP sensor.
- Connect the engine wiring harness electrical connector (2) to the EVAP canister purge solenoid valve.
- Connect the engine wiring harness electrical connector to the generator.
- Connect the left side engine wiring harness electrical connector (2) to the main ignition coil electrical connector.
- Install the left side CPA retainer (3) to the engine wiring harness main ignition coil electrical connector.
- Connect the left side engine wiring harness electrical connectors (1) to the fuel injectors.
- Perform the following steps in order to connect the fuel injector electrical connectors:
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. |
- Connect the engine wiring harness electrical connector (1) to the ETC.
- Connect the right side engine wiring harness electrical connector (3) to the main ignition coil electrical connector.
- Install the right side CPA retainer (4) to the engine wiring harness main ignition coil electrical connector.
- Connect the right side engine wiring harness electrical connectors (2) to the fuel injectors.
- Perform the following steps in order to connect the fuel injector electrical connectors:
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. |
- Connect the engine harness wiring harness electrical connector (1) to the MAF/IAT sensor.
- Connect the engine wiring harness electrical connector (3) to the A/C compressor pressure switch.
- Install the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Use the following procedure in order to inspect for leaks:
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. |