Intake Manifold Replacement Upper

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement in Engine Electrical.

Remove the intake air resonator from the throttle body.

2. Remove the air cleaner intake duct from the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls.



3. Remove the crankcase vent tube from the throttle body.



4. Remove the PCV valve from the valve rocker arm cover.
5. Remove the EGR pipe from the upper intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.
6. Remove Left and Right Side Secondary AIR Injection Pipe. If so Equipped.
7. Remove the throttle body from the upper intake manifold. Refer to Throttle Body Removal .
8. Remove the EVAP canister solenoid valve. Refer to Evaporative Emission Canister Replacement in Engine Controls.



9. Remove the upper intake manifold bolts.
10. Remove the upper intake manifold and gaskets.
11. Clean the excessive carbon deposit from the exhaust and the EGR valve passages. Refer to Cylinder Head Cleaning and Inspection .

1. Install the upper intake manifold gaskets.

Important: Failure to follow the procedure listed, could cause a driveability problem.

2. Install the upper intake manifold.
3. Coat a minimum of eight threads of the bolts with thread locking sealant.




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.

4. Install the upper intake manifold bolts.

Tighten
Tighten the bolts in the following manner:

4.1.	Tighten the bolts in sequence to 8 N·m (72 lb in).

4.2.	Re tighten the bolts in sequence to 18 N·m (13 lb ft).

5. Install the EGR valve if necessary. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.



6. Install the EGR pipe to the upper intake manifold.

Tighten
Tighten EGR valve fittings to 60 N·m (46 lb ft).

7. Install Left and Right Side Secondary AIR Injection Pipes. If so equipped.
8. Install the EVAP canister solenoid valve to the intake manifold. Refer to Evaporative Emission Canister Replacement in Engine Controls.
9. Install the throttle body to the upper intake manifold. Refer to Throttle Body Installation in Engine Controls.



10. Install the PCV valve to the valve rocker arm cover to the cylinder head.



11. Install the crankcase vent tube to the valve rocker arm cover.



12. Install the air cleaner resonator to the throttle body.
13. Install the intake air intake duct (1) to the throttle body. Refer to Air Cleaner Assembly Replacement in Engine Controls-7.4L.
14. Connect the battery negative cables to the battery. Refer to Battery Cable Replacement in Engine Electrical.

Intake Manifold Replacement Lower

Important: The lower intake manifold gaskets and seal are reusable. Replace only the gaskets and seals if they are damaged.

1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Remove the upper Intake Manifold. Refer to Intake Manifold Replacement .
3. Remove the MAP sensor from the lower intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
4. Remove the radiator outlet hose. Refer to Radiator Hose Replacement in Engine Cooling.
5. Remove the thermostat housing from the lower intake manifold. Refer to Engine Coolant Thermostat Housing Replacement in Engine Cooling.
6. Remove the heater hoses from the heater core. Refer to Radiator Hose Replacement in Engine Cooling.
7. Remove the coolant bypass hose from the lower intake manifold and the water pump.
8. Remove the fuel rail from the lower intake manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.



9. Remove the lower intake manifold bolts from the engine head.
10. Remove the lower intake manifold from the cylinder head.
11. Remove the lower intake manifold gaskets and seals from the cylinder head.
12. Clean all sealing surfacces of oil and grease. Refer to Intake Manifold Cleaning and Inspection .

1. Install the lower intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
2. Install the lower intake manifold to the engine block.
3. Apply thread locking sealer to the lower intake manifold bolts.




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.

4. Install the lower intake manifold bolts to the engine head.

Tighten
Tighten the bolts to 30 N·m (22 lb ft).

Re-tighten the bolts to 40 N·m (30 lb ft).

5. Install the MAP sensor to the lower intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.
6. Install the fuel rail to the lower intake manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.
7. Install the thermostat housing to the lower intake manifold. Refer to Engine Coolant Thermostat Housing Replacement in Engine Cooling.
8. Install the coolant bypass hose to the water pump.
9. Install the heater hoses to the lower intake manifold. Refer to Heater Water Shutoff Valve Replacement in Engine Cooling.
10. Install the radiator outlet hose to the lower intake manifold. Refer to Radiator Hose Replacement in Engine Cooling.
11. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement .
12. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.