Aurora 2001-2003

Intake Manifold

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Partially drain the engine coolant.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Disengage the snap-lock retainers by pushing toward the camshaft covers and lifting.


    NOTE
    The manifold-to-cylinder head seals are reusable unless cut or damaged.



    Air duct from the throttle body
     
    Fuel injector sight shield
     
    Accelerator cable and bracket
     
    Cruise control cable and bracket
     
    Coolant hoses from the throttle body
     
    Fuel lines from the fuel supply rail
     
    Fuel vapor line from the Evaporative Emission (EVAP) canister purge solenoid
     
    Brake booster vacuum hose
     
    Air conditioning vacuum hose from the engine
     
    Surge tank inlet pipe retainer from the fuel supply rail
     
    Fuel injector electrical connectors
     
    Throttle Position Sensor (TPS) electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Evaporative Emission (EVAP) canister purge solenoid connector
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Wiring harness from the camshaft covers
     
    Vacuum hose from the fuel pressure regulator and throttle body
     
    Positive Crankcase Ventilation (PCV) tubes from both camshaft covers and the intake manifold
     
    Exhaust Gas Recirculation (EGR) valve outlet pipe
     
    Fuel supply rail with injectors
     



    Intake manifold
     



    Click image to see an enlarged view

    Fig. Intake manifold assembly-3.5L engine

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.5L engine

  1. Install or connect the following:

    Intake manifold with new gaskets (if necessary). Torque the bolts in sequence to 89 inch lbs. (10 Nm).
     
    New O-rings on the fuel injectors
     
    Fuel supply rail with the injectors
     
    EGR pipe. Torque the intake manifold bolts to 89 inch lbs. (10 Nm) and the coolant crossover bolt to 18 ft. lbs. (24 Nm).
     
    PCV valve and feed tubes
     
    Fuel pressure regulator vacuum hose
     
    Engine wiring harness to the camshaft covers. Torque the bolts to 89 inch lbs. (10 Nm).
     
    TPS electrical connector
     
    IAC valve electrical connector
     
    EVAP solenoid electrical connector
     
    MAP sensor electrical connector
     
    Fuel injector electrical connectors
     
    Surge tank pipe retainer to the fuel supply rail
     
    A/C vacuum hose
     
    Brake booster vacuum hose
     
    Vapor line to the EVAP canister purge solenoid
     
    Fuel lines to the fuel supply rail
     
    Coolant hoses to the throttle body
     
    Cruise control cable and bracket
     
    Accelerator cable and bracket
     
    Fuel injector sight shield
     
    Air duct to the throttle body
     
    Negative battery cable
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

4.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Fuel injector sight shield
     
    Ignition module connectors
     
    Positive Crankcase Ventilation (PCV) valve
     
    PCV fresh air tube
     
    Fuel regulator vacuum tube
     
    Secondary Air Injection (AIR) solenoid vacuum tubes
     
    Fuel lines at the fuel rail
     
    Engine coolant heater wire
     
    Fuel injector electrical connectors
     
    Fuel rail with injectors
     
    Plenum duct clamp
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-4.0L engine

  1. Install or connect the following:

    Intake manifold with a new gasket. Torque the bolts in sequence to 89 inch lbs. (10 Nm).
     
    Torque the plenum duct clamp to 20 inch lbs. (2.25 Nm)
     
    Fuel rail with the injectors. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Fuel injector electrical connectors
     
    Engine coolant heater wire
     
    Fuel lines to the fuel rail
     
    AIR solenoid vacuum tubes
     
    Fuel regulator vacuum tube
     
    PCV fresh air tube
     
    PCV valve
     
    Ignition module connectors
     

  2.  
  3. Pressurize the fuel system and check for leaks.
  4.  
  5. Install the fuel injector sight shield. Torque the bolts to 27 inch lbs. (3 Nm).
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Fuel injector sight shield
     
    Ignition module connectors
     
    Positive Crankcase Ventilation (PCV) valve
     
    PCV fresh air tube
     
    Fuel regulator vacuum tube
     
    Secondary Air Injection (AIR) solenoid vacuum tubes
     
    Fuel lines at the fuel rail
     
    Engine coolant heater wire
     
    Fuel injector electrical connectors
     
    Fuel rail with injectors
     
    Plenum duct clamp
     
    Intake manifold
     

  6.  

To install:

  1. Install or connect the following:

    Intake manifold with a new gasket. Torque the bolts to 89 inch lbs. (10 Nm) and the plenum duct clamp to 20 inch lbs. (2.25 Nm).
     
    Fuel rail with the injectors. Torque the bolts to 35 inch lbs. (4 Nm).
     
    Fuel injector electrical connectors
     
    Engine coolant heater wire
     
    Fuel lines to the fuel rail
     
    AIR solenoid vacuum tubes
     
    Fuel regulator vacuum tube
     
    PCV fresh air tube
     
    PCV valve
     
    Ignition module connectors
     

  2.  
  3. Pressurize the fuel system and check for leaks.
  4.  
  5. Install the fuel injector sight shield. Torque the bolts to 27 inch lbs. (3 Nm).
  6.  

 
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