Intake Manifold Replacement V8 Upper

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 battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
2. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls. 
4. Disconnect the following electrical connectors:

•	Fuel injector electrical connector

•	Manifold absolute pressure (MAP) sensor

•	Canister purge solenoid

•	Idle air control (IAC) solenoid

•	Throttle position (TP) sensor

5. Remove the vacuum brake booster hose, if equipped.
6. Remove the PCV at the intake manifold.
7. Twist to unlock the PCV.
8. Disconnect the spark plug wires from the left side of the distributor cap. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
9. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls. 
10. Remove the canister purge solenoid from the engine. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls. 
11. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement
12. Remove the accelerator control cable bracket from the throttle body and set it aside.



13. Remove the upper intake manifold from the engine.
14. Clean all sealing surfaces. Refer to Intake Manifold Clean and Inspect

1. Install the upper intake manifold to the engine.

Refer to Intake Manifold Assemble

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 accelerator control cable bracket to the throttle body.

Tighten
Tighten the nuts to 10 N·m (88 lb in).

3. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
4. Install the canister purge solenoid to the engine. Refer to EVAP Canister Purge Solenoid Valve Replacement in Engine Controls.
5. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls. 
6. Connect the spark plug wires to the left side of the distributor cap. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
7. Install the PCV to the intake manifold. Twist to lock the PCV.
8. Install the vacuum brake booster hose to the intake manifold, if equipped.
9. Install the vacuum brake booster hose to the intake manifold, if equipped.
10. Connect the following electrical connectors:

•	Fuel injector electrical connector

•	Manifold absolute pressure (MAP) sensor

•	Canister purge solenoid

•	Idle air control (IAC) solenoid

•	Throttle position (TP) sensor

11. Install the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
13. Connect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.

Intake Manifold Replacement V8 Lower

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
4. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
5. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
6. Remove the following coolant hoses:

•	Upper radiator hose--Refer to Radiator Hose Replacement in Engine Cooling.

•	Both heater hoses

•	Coolant by-pass hose

7. Disconnect the following electrical connectors:

•	SCPI injector electrical connector

•	Manifold absolute pressure (MAP) sensor

•	Canister purge solenoid

•	Idle air control (IAC) motor

•	Throttle position (TP) sensor

•	Exhaust gas recirculation (EGR) valve

•	Engine coolant temperature (ECT) sensor

8. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped.
9. Remove the PCV at the intake manifold, twist to unlock.
10. Remove the distributor from the engine. Refer to Distributor Replacement .
11. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
12. Remove the accelerator control cable and the cruise control cables, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement .
13. Remove the accelerator control cable bracket from the throttle body.
14. Remove the ignition coil and ICM bracket. Refer to Ignition Coil and Ignition Coil Module Replacement .



15. Remove the EGR inlet pipe from the intake manifold.

Important: It is not necessary to discharge the A/C refrigerant.

16. Remove the air conditioning (A/C) compressor, if equipped, and set it aside. Refer to Air Conditioning Compressor Replacement in HVAC.
17. Remove the power steering pulley from the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.



18. Remove the power steering pump mounting bracket using the following procedure:

•	Remove two nuts from the back of the power steering pump.

•	Remove the nut from the stud.

•	Remove the three bolts from the mounting bracket.

•	Slide the power steering pump mounting bracket forward, with the power steering pump still attached.

•	Lay the pump and the bracket aside.

19. Remove one valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
20. Remove the lower intake manifold from the engine. Refer to Intake Manifold Removal .
21. Clean all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection .

1. Install the lower intake manifold to the engine. Refer to Intake Manifold Installation .
2. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .

Notice: Refer to Fastener Notice in the Preface section.




3. Install the power steering pump mounting bracket using the following procedure:

•	Install the power steering pump bracket onto the stud.

•	Install the nut onto the stud finger tight.

•	Install the three bolts finger tight.

•	Install the two nuts to the back of the power steering pump finger tight.

Tighten
Tighten the nuts and the bolts to 44 N·m (32 lb ft).




4. Install the power steering pump pulley to the power steering pump. Refer to Power Steering Pump Replacement in Steering.
5. Connect the electrical connector to the power steering pump.
6. Install the air conditioning (A/C) compressor, if equipped. Refer to Air Conditioning Compressor Replacement in HVAC.



7. Connect the exhaust gas recirculation (EGR) pipe to the bracket and the front of the intake manifold.
8. Install the ignition coil and the ICM bracket. Refer to Ignition Coil and Ignition Coil Module Replacement .
9. Install the accelerator control cable bracket to the throttle body.
10. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
11. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
12. Install the distributor to the engine. Refer to Distributor Replacement .
13. Install the PCV at intake manifold using a twisting motion in order to lock.
14. Install the vacuum brake booster hose, if equipped.
15. Connect the following electrical connectors:

•	SCPI injector electrical connector

•	Manifold absolute pressure (MAP) sensor

•	Canister purge solenoid

•	Idle air control (IAC) motor

•	Throttle position (TP) sensor

•	Exhaust gas recirculation (EGR) valve

•	Engine coolant temperature (ECT) sensor

16. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
17. Install the engine cover. Refer to Engine Cover Replacement Engine Cover in Interior Trim.
18. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
19. Fill the engine with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
20. Connect the battery negative cable. Refer to Battery Cable Replacement in Engine Electrical.