9-3 1999

Intake Manifold

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Removal & Installation



2.0L & 2.3L Engines

CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Rubber elbow running between the throttle housing and the turbocharger, if equipped
     
    Throttle Position (TP) sensor connector
     
    Hoses at the throttle housing
     
    Throttle housing
     
    Oil filler pipe bracket at the manifold. Position it out of the way.
     
    All hoses and lines attached to the manifold. Label them prior to removal.
     
    Idle Air Control (IAC) valve
     
    Fuel line from the pressure regulator
     
    Banjo fitting connecting the fuel line to the fuel rail
     
    Fuel line and pulsator
     
    Each fuel injector electrical lead
     
    Temperature sensor
     
    Ground wires at the manifold
     
    Harness assembly from underneath the manifold
     
    Exhaust Gas Recirculation (EGR) pipe and all connectors
     
    Intake manifold
     

  8.  

To install:

  1. Scrape off any excess gasket material
  2.  
  3. Install or connect the following;

    Intake manifold with a new gasket and torque the bolts in a crisscross pattern to 16 ft. lbs. (22 Nm)
     
    Wire harness
     
    EGR pipe
     
    Ground wires
     
    Temperature sensor
     
    Injector leads
     
    Fuel line to the pressure regulator
     
    Fuel line/pulsator to the fuel rail
     
    Oil filler pipe bracket to the manifold
     
    IAC valve
     
    Throttle housing
     
    TP sensor connector
     
    Rubber elbow between the turbocharger and the intake manifold, if equipped
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

3.0L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine covers
     
    Cruise control cable
     
    Throttle cable
     
    Control rod
     
    Intake tube from the Mass Air Flow (MAF) sensor assembly
     
    Vacuum hoses and electrical connectors from MAF assembly
     
    MAF assembly
     
    Hoses and wiring from the upper intake manifold. Label prior to removal.
     
    Upper intake manifold
     
    Idle Air Control (IAC) valve
     
    Fuel pressure regulator hose
     
    Harness from under the throttle plate housing
     
    Injector electrical harness
     
    Camshaft Position (CMP) sensor connector
     
    Fuel line
     
    Lower intake manifold
     

  4.  

To install:

Click image to see an enlarged view

Fig. Intake manifold bolt tightening sequence-3.0L engine

  1. Install or connect the following:

    Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Injector wiring
     
    CMP sensor
     
    Upper intake manifold with new gaskets
     
    Throttle plate housing and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Wiring and hoses
     
    IAC valve
     
    Hose to the fuel pressure regulator
     
    MAF assembly and hoses
     
    Throttle control rod
     
    Cruise control cable
     
    Engine covers
     
    Negative battery cable
     

  2.  

 
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