Aura, Outlook 2007

Intake Manifold

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Removal & Installation



3.5L Engine
Lower Manifold

NOTE
This engine uses a sequential multiport fuel injection system. Injector wiring harness connectors must be connected to their appropriate fuel injector or exhaust emissions and engine performance may be seriously affected.

  1. Remove the upper intake manifold.
  2.  
  3. Remove the valve rocker arm covers.
  4.  
  5. Remove the coolant crossover pipe.
  6.  
  7. Disconnect the fuel injector wiring harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
  8.  
  9. Disconnect the engine wiring harness electrical connector from the fuel injector inline electrical connector.
  10.  
  11. Disconnect the fuel injector wiring harness electrical connector from the Camshaft Position (CMP) sensor.
  12.  
  13. Remove the fuel injector wiring harness connector bracket bolt from the intake manifold.
  14.  
  15. Remove the fuel rail bolts and rail.
  16.  
  17. Remove the lower intake manifold bolts.
  18.  
  19. Remove the lower intake manifold.
  20.  
  21. Remove the rocker arms.
  22.  
  23. Remove the push rods.
  24.  
  25. Remove the lower intake manifold gaskets and seals.
  26.  
  27. Clean the lower intake manifold gasket mating surfaces.
  28.  

To install:


NOTE
RTV sealer is NOT to be placed under the lower intake manifold gaskets. Install the lower intake manifold gaskets and seals.

  1. Install the pushrods and rocker arms.

    Click image to see an enlarged view

    Fig. Apply a small drop, 0.31-0.39 in. (8-10mm) of RTV sealer to the 4 corners of the intake manifold to block joints (1)-3.5L engine

  2.  
  3. With the NEW gaskets and seals in place, apply a small drop, 0.31-0.39 in. (8-10mm) of RTV sealer to the 4 corners of the intake manifold to block joints (1).
    NOTE
    Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.


    NOTE
    Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak. Apply sealer to the lower intake manifold bolt threads.



    Click image to see an enlarged view

    Fig. Lower intake manifold torque sequence-3.5L engine

  4.  
  5. Install the lower intake manifold bolts and tighten the lower intake manifold bolts in the sequence as follows:
    1. Bolts 1, 2, 3, 4 to 12 ft. lbs. (16 Nm).
    2.  
    3. Bolts 5, 6, 7, 8 to 18 ft. lbs. (25 Nm).
    4.  

  6.  
  7. Inspect the fuel rail, fuel injectors for damage and replace as necessary.
  8.  
  9. Lubricate with clean engine oil and install NEW injector lower O-rings seals onto the injectors.
  10.  
  11. Install the injector nozzles into the lower intake manifold injector bores.
  12.  
  13. Press on the injector rail using the palms of both hands until the injectors are fully seated.
  14.  
  15. Install the fuel injector rail bolts and tighten to 10 ft. lbs. (14 Nm).
  16.  
  17. Position the fuel injector wiring harness electrical connector bracket to the intake manifold and install the bolt. Tighten to 10 ft. lbs. (14 Nm).
  18.  
  19. Connect the fuel injector wiring harness electrical connector to the CMP sensor.
  20.  
  21. Connect the engine wiring harness electrical connector to the fuel injector inline electrical connector.
  22.  
  23. Connect the fuel injector wiring harness electrical connector to the ECT sensor.
  24.  
  25. Install the coolant crossover pipe.
  26.  
  27. Install the valve rocker arm covers.
  28.  
  29. Install the upper intake manifold. Top of Form Bottom of Form
  30.  

Upper Manifold
  1. Remove the intake manifold cover.
  2.  
  3. Disconnect the fuel feed pipe quick connect fitting from the fuel rail.
  4.  
  5. Disconnect the Evaporative Emission (EVAP) pipe quick connect fitting from the purge solenoid.
  6.  
  7. Remove the fuel line clip from the Manifold Absolute Pressure (MAP) sensor bracket.
  8.  
  9. Reposition the fuel/EVAP lines out of the way.
  10.  
  11. Drain and recycle the engine coolant.
  12.  
  13. Remove the air cleaner outlet duct.
  14.  
  15. Remove the Positive Crankcase Ventilation (PCV) fresh air tube from the rocker cover.
  16.  
  17. Remove the PCV foul air tube quick connect fitting from the rocker cover.
  18.  
  19. Remove the PCV foul air tube from the intake manifold.
  20.  
  21. Reposition the brake booster vacuum hose clamp at the intake manifold.
  22.  
  23. Remove the brake booster vacuum hose from the intake manifold.
  24.  
  25. Reposition the radiator surge tank inlet hose clamp.
  26.  
  27. Remove the radiator surge tank inlet hose from the inlet pipe.
  28.  
  29. Remove the radiator surge tank inlet pipe bolts.
  30.  
  31. Remove the radiator surge tank inlet pipe.
  32.  
  33. Remove and discard the O-ring seal.
  34.  
  35. Disconnect the engine wiring harness electrical connector from the MAP sensor.
  36.  
  37. Disconnect the engine wiring harness electrical connector from the EVAP canister purge solenoid.
  38.  
  39. Disconnect the engine wiring harness electrical connector from the electronic throttle control (ETC).
  40.  
  41. Disconnect the left side spark plug wires from the spark plugs.
  42.  
  43. Disconnect the left side spark plug wires from the ignition coil.
  44.  
  45. Disengage the spark plug wire retainer clips from the heater inlet and outlet pipe bracket and the MAP sensor bracket.
  46.  
  47. Remove the left side spark plug wires.
  48.  
  49. Remove the heater inlet and outlet pipe nuts from the throttle body studs.
  50.  
  51. Reposition the heater inlet and outlet hose clamps from the pipes.
  52.  
  53. Remove the heater inlet and outlet hoses from the heater inlet and outlet pipes.
  54.  
  55. Remove the heater inlet and outlet pipe bracket from the throttle body studs. Reposition the inlet and outlet pipe out of the way.
  56.  
  57. Remove the ignition coil bracket bolts.
  58.  
  59. Remove the alternator rear brace upper nut.
  60.  
  61. Remove the alternator through bolt.
  62.  
  63. Remove the alternator rear brace.

    Click image to see an enlarged view

    Fig. Upper intake manifold mounting-3.5L engine

  64.  
  65. Remove the upper intake manifold bolts and stud.
  66.  
  67. Separate and remove the upper intake manifold from the lower intake manifold.
  68.  
  69. Remove the upper to lower intake manifold gaskets.
  70.  

To install:

  1. Install the NEW upper to lower intake manifold gaskets.
  2.  
  3. Install the upper intake manifold onto the lower intake manifold.
  4.  
  5. Apply threadlock to the upper intake manifold bolts/stud threads.
  6.  
  7. Install the upper intake manifold bolts and stud and tighten to 18 ft. lbs. (25 Nm).
  8.  
  9. Place the alternator rear brace onto the stud.
  10.  
  11. Install the alternator through bolt until snug.
  12.  
  13. Install the alternator rear brace upper nut until snug.
  14.  
  15. Tighten the alternator through bolt to 37 ft. lbs. (50 Nm) and the rear brace upper nut to 18 ft. lbs. (25 Nm).
  16.  
  17. Install the ignition coil bracket bolts and tighten to 18 ft. lbs. (25 Nm).
  18.  
  19. Position the inlet and outlet pipe and install the heater inlet and outlet pipe bracket to the throttle body studs.
  20.  
  21. Install the heater inlet and outlet hoses to the heater inlet and outlet pipes.
  22.  
  23. Position the heater inlet and outlet hose clamps to the pipes.
  24.  
  25. Install the heater inlet and outlet pipe nuts to the throttle body studs.
  26.  
  27. Install the left side spark plug wires.
  28.  
  29. Connect the left side spark plug wires to the spark plugs.
  30.  
  31. Connect the left side spark plug wires to the ignition coil.
  32.  
  33. Engage the spark plug wire retainer clips to the heater inlet and outlet pipe bracket and the MAP sensor bracket.
  34.  
  35. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid.
  36.  
  37. Connect the engine wiring harness electrical connector to the ETC.
  38.  
  39. Connect the engine wiring harness electrical connector to the MAP sensor.
  40.  
  41. Install a NEW O-ring seal to the inlet pipe.
  42.  
  43. Install the radiator surge tank inlet pipe.
  44.  
  45. Install the radiator surge tank inlet hose to the inlet pipe and fasten the clamp.
  46.  
  47. Install the remaining components in the reverse order of removal. Bottom of Form
  48.  

3.6L Engine
Lower Manifold
  1. Remove the fuel injectors and fuel rail.
  2.  
  3. Remove the lower intake manifold bolts.
  4.  
  5. Remove the lower intake manifold and gasket. Discard the gasket.
  6.  
  7. Clean and inspect the intake manifold and mating surfaces.
  8.  

To install:

  1. Place a NEW lower intake manifold gasket onto the cylinder heads.
  2.  
  3. Place the lower intake manifold onto the cylinder heads.
  4.  
  5. Install the lower intake manifold bolts and tighten to 17 ft. lbs. (23 Nm).
  6.  
  7. Install the fuel injectors and fuel rail.
  8.  

Upper Manifold
  1. Remove the fuel injector sight shield.
  2.  
  3. Remove the air cleaner outlet duct.
  4.  
  5. Disconnect the fuel feed line quick connect fitting from the fuel rail.
  6.  
  7. Remove the fuel feed pipe line nut and remove the fuel feed line clip from the stud.
  8.  
  9. Reposition the fuel feed line out of the way.
  10.  
  11. Remove the coolant air bleed hose/pipe clip bolt from the upper intake manifold.
  12.  
  13. Reposition the coolant air bleed hose clamp at the water outlet.
  14.  
  15. Remove the coolant air bleed hose from the water outlet.
  16.  
  17. Remove the coolant air bleed hose/pipe clip from the upper intake manifold stud and reposition out of the way.
  18.  
  19. Reposition the brake booster vacuum hose clamp at the upper intake manifold.
  20.  
  21. Remove the brake booster vacuum hose from the upper intake manifold.
  22.  
  23. Disconnect the engine wiring harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  24.  
  25. Disconnect the engine wiring harness electrical connector from the electronic throttle control (ETC).
  26.  
  27. Disconnect the engine wiring harness electrical connector from the intake manifold tuning valve.
  28.  
  29. Disconnect the engine wiring harness electrical connector from the Evaporative Emission (EVAP) canister purge solenoid.
  30.  
  31. Disconnect the Positive Crankcase Ventilation (PCV) tube from the upper intake manifold and reposition aside.
  32.  
  33. Disconnect the EVAP canister purge solenoid tube quick connect fitting at the upper intake manifold and reposition aside.
  34.  
  35. Remove the fuel rail to bracket bolt.
  36.  
  37. Remove the fuel rail wiring harness electrical connector bolt and reposition the harness out of the way.
  38.  
  39. Remove the upper intake bolts.
  40.  
  41. Remove the upper intake manifold and gaskets. Discard gaskets.
  42.  
  43. Clean the gasket mating surfaces.
  44.  

To install:

  1. Place NEW upper intake manifold gaskets onto the lower intake manifold.
  2.  
  3. Place the upper intake manifold onto the lower intake manifold.
  4.  
  5. Install the upper intake bolts and tighten to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Upper intake manifold mounting-3.6L engine

  6.  
  7. Position the fuel rail wiring harness and install the fuel rail wiring harness electrical connector bolt Tighten to 89 in. lbs. (10 Nm). Tighten
  8.  
  9. Install the fuel rail to bracket bolt. Tighten to 89 in. lbs. (10 Nm).
  10.  
  11. Position and install the EVAP canister purge solenoid tube quick connect fitting to the upper intake manifold.
  12.  
  13. Position and install the PCV tube to the upper intake manifold.
  14.  
  15. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid.
  16.  
  17. Connect the engine wiring harness electrical connector to the intake manifold tuning valve.
  18.  
  19. Connect the engine wiring harness electrical connector to the ETC.
  20.  
  21. Connect the engine wiring harness electrical connector to the MAP sensor.
  22.  
  23. Install the brake booster vacuum hose to the upper intake manifold.
  24.  
  25. Position the brake booster vacuum hose clamp at the upper intake manifold.
  26.  
  27. Position and install the coolant air bleed hose/pipe clip to the upper intake manifold stud.
  28.  
  29. Install the coolant air bleed hose to the water outlet.
  30.  
  31. Position the coolant air bleed hose clamp at the water outlet.
  32.  
  33. Install the coolant air bleed hose/pipe clip bolt to the upper intake manifold. Tighten to 89 in. lbs. (10 Nm).
  34.  
  35. Position the fuel feed line and install the fuel feed line clip to the stud. Install the fuel feed line nut. Tighten to 89 in. lbs. (10 Nm).
  36.  
  37. Connect the fuel feed line quick connect fitting to the fuel rail.
  38.  
  39. Install the air cleaner outlet duct.
  40.  
  41. Install the fuel injector sight shield.
  42.  

 
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