G6 2005-2007

Intake Manifold

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Removal & Installation



3.5L Engine
Lower Manifold
  1. Release the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the upper intake manifold.
  6.  
  7. Remove the valve covers.
  8.  
  9. Disconnect the engine coolant temperature (ECT) wiring harness.
  10.  
  11. Disconnect and remove the fuel injector and manifold air pressure (MAP) wiring harness.
  12.  
  13. Remove the fuel injector rail.
  14.  
  15. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition.
  16.  
  17. Disconnect the radiator inlet hose from the engine.
  18.  
  19. Remove the thermostat housing and thermostat.
  20.  
  21. Remove the lower intake manifold bolts.
  22.  
  23. Remove the lower intake manifold.
  24.  
  25. Remove the valve rocker arms and pushrods.
  26.  
  27. Remove the lower intake manifold gaskets and seals.
  28.  
  29. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  30.  
  31. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
  32.  
  33. Remove all the loose RTV sealer.
  34.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold tightening sequence -3.5L engine

  1. Install the lower intake manifold gaskets.
  2.  
  3. Install the valve rocker arms and pushrods.
  4.  
  5. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer to the 4 corners of the intake manifold to block joints.
  6.  
  7. Install the lower intake manifold.
  8.  
  9. Apply sealer to the lower intake manifold bolt threads.
  10.  
  11. Install the lower intake manifold bolts and tighten in sequence as follows:
    1. Tighten the bolts in sequence to 115 inch lbs. (13 Nm),
    2.  
    3. Tighten bolts (1, 2, 3, and 4) in sequence to 15 ft. lbs. (20 Nm on the final pass.
    4.  
    5. Tighten bolts (5, 6, 7, and 8) in sequence to 18 ft. lbs. (25 Nm (18 lb ft) on the final pass.
    6.  

  12.  
  13. Install the heater inlet pipe and tighten to 18 ft. lbs. (25 Nm).
  14.  
  15. Install the thermostat and housing.
  16.  
  17. Install the ECT sensor.
  18.  
  19. Connect the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
  20.  
  21. Connect the radiator inlet hose to the engine.
  22.  
  23. Connect the heater inlet pipe and heater hose to the lower intake manifold.
  24.  
  25. Install the power steering pump to the front engine cover.
  26.  
  27. Install the fuel injector rail.
  28.  
  29. Connect the fuel feed pipe to the fuel injector rail.
  30.  
  31. Connect the fuel injector and MAP wiring harness.
  32.  
  33. Connect the ECT wiring harness.
  34.  
  35. Install the valve rocker arm covers.
  36.  
  37. Install the upper intake manifold.
  38.  
  39. Connect the negative battery cable.
  40.  

Upper Manifold
  1. Release the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the intake manifold cover.
  6.  
  7. Remove the vacuum hoses from the following:
    1. Evaporative emissions (EVAP) canister purge valve
    2.  
    3. Manifold vacuum source
    4.  
    5. Brake booster
    6.  
    7. Heater and air conditioning (A/C) source
    8.  

  8.  
  9. Disconnect the electrical connectors from the following:
    1. Exhaust Gas Recirculation (EGR) valve
    2.  
    3. Mass Air Flow (MAF) sensor
    4.  
    5. Intake Air Temperature (IAT) sensor
    6.  
    7. Electronic throttle control
    8.  
    9. EVAP canister purge valve
    10.  

  10.  
  11. Remove the air cleaner intake duct.
  12.  
  13. Remove the left side spark plug wires from the spark plugs.
  14.  
  15. Remove the following wiring harnesses from the retainers:
    1. Camshaft position (CMP) sensor wiring harness
    2.  
    3. Left side spark plug wire harness
    4.  
    5. Engine wiring harness
    6.  

  16.  
  17. Remove the ignition coil bracket with the coils.
  18.  
  19. Remove the EVAP canister purge solenoid valve.
  20.  
  21. Remove the Manifold Absolute Pressure (MAP) sensor and the bracket.
  22.  
  23. Remove the EGR valve.
  24.  
  25. Remove the upper intake manifold bolts and the stud.
  26.  
  27. Remove the upper intake manifold.
  28.  
  29. Remove the upper intake manifold gaskets.
  30.  

To install:

Click image to see an enlarged view

Fig. Upper intake manifold mounting-3.5L engine

  1. Install the throttle body.
  2.  
  3. Install the upper intake manifold gaskets.
  4.  
  5. Install the upper intake manifold.
  6.  
  7. Install the right upper intake manifold bolts and the stud and tighten to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the EGR valve.
  10.  
  11. Install the MAP sensor bracket and the sensor.
  12.  
  13. Install the EVAP canister purge solenoid valve.
  14.  
  15. Install the ignition coil bracket with the coils.
  16.  
  17. Install the following wiring harnesses to the retainers:
    1. Engine wiring harness
    2.  
    3. Left side spark plug wire harness
    4.  
    5. CMP sensor wiring harness
    6.  

  18.  
  19. Install the left side spark plug wires to the spark plugs.
  20.  
  21. Install the air cleaner intake duct.
  22.  
  23. Connect the electrical connectors to the following:
    1. EVAP canister purge valve
    2.  
    3. Electronic throttle control
    4.  
    5. IAT sensor
    6.  
    7. MAF sensor
    8.  
    9. EGR valve
    10.  

  24.  
  25. Install the vacuum hoses to the following: Heater and A/C source, brake booster, manifold vacuum, and EVAP canister purge valve.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Fill the cooling system.
  30.  
  31. Install the intake manifold cover.
  32.  

3.6L Engine
Lower Manifold
  1. Release the fuel system pressure.
  2.  
  3. Remove the fuel injector sight shield.
  4.  
  5. Disconnect the engine wiring harness electrical connector from the fuel injector wiring harness electrical connector.
  6.  
  7. Disconnect the fuel feed pipe quick connect fitting from the fuel rail.
  8.  
  9. Remove the upper intake manifold.
  10.  
  11. Use compressed air in order to remove any debris from the around the area where the fuel injectors enter the lower intake manifold.
  12.  
  13. Remove the fuel rail bolts.
    NOTE
    Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

  14.  
  15. Remove the fuel rail with fuel injectors from the lower intake manifold.
  16.  
  17. Remove the lower intake manifold bolts.
  18.  
  19. Remove the lower intake manifold and gasket. Discard the gasket.
  20.  
  21. Clean and inspect the intake manifold and sealing surfaces.
  22.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold and related parts -3.6L engine

  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. Tighten fuel rail mounting bolts to 89 inch. lbs. (10 Nm).
  8.  
  9. Install upper intake manifold, fuel line quick connect fitting, electrical harness and shield.
  10.  

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. If replacing the upper intake manifold complete the following steps:

    Remove the MAP sensor.
     
    Remove the throttle body.
     
    Remove the EVAP canister purge solenoid valve.
     
    Remove the intake manifold tuning valve.
     

  44.  

To install:

  1. If the upper intake manifold was replaced complete the following steps:

    Install the MAP sensor.
     
    Install the throttle body.
     
    Install the EVAP canister purge solenoid valve.
     
    Install the intake manifold tuning valve.
     

  2.  
  3. Place NEW upper intake manifold gaskets onto the lower intake manifold.
  4.  
  5. Place the upper intake manifold onto the lower intake manifold.
  6.  
  7. Install the upper intake bolts and tighten to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Upper intake manifold -3.6L engine and mounting bolts shown

  8.  
  9. Position the fuel rail wiring harness, install the fuel rail wiring harness electrical connector bolt and tighten bolt to 89 inch. lbs. (10 Nm).
  10.  
  11. Install the fuel rail to bracket bolt, tighten bolt to 89 inch. lbs. (10 Nm).
  12.  
  13. Position and install the EVAP canister purge solenoid tube quick connect fitting to the upper intake manifold.
  14.  
  15. Position and install the PCV tube to the upper intake manifold.
  16.  
  17. Connect the engine wiring harness electrical connector to the EVAP canister purge solenoid.
  18.  
  19. Connect the engine wiring harness electrical connector to the intake manifold tuning valve.
  20.  
  21. Connect the engine wiring harness electrical connector to the ETC.
  22.  
  23. Connect the engine wiring harness electrical connector to the MAP sensor.
  24.  
  25. Install the brake booster vacuum hose to the upper intake manifold.
  26.  
  27. Position the brake booster vacuum hose clamp at the upper intake manifold.
  28.  
  29. Position and install the coolant air bleed hose/pipe clip to the upper intake manifold stud.
  30.  
  31. Install the coolant air bleed hose to the water outlet.
  32.  
  33. Position the coolant air bleed hose clamp at the water outlet.
  34.  
  35. Install the coolant air bleed hose/pipe clip bolt to the upper intake manifold, tighten bolt to 89 inch. lbs. (10 Nm).
  36.  
  37. Position the fuel feed line and install the fuel feed line clip to the stud.
  38.  
  39. Install the fuel feed line nut and tighten to 89 inch. (10 Nm).
  40.  
  41. Connect the fuel feed line quick connect fitting to the fuel rail.
  42.  
  43. Install the air cleaner outlet duct.
  44.  
  45. Install the fuel injector sight shield.
  46.  

3.9L Engine
Lower Manifold
  1. Drain the cooling system.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the coolant crossover pipe.
  6.  
  7. Remove the upper intake manifold.
  8.  
  9. Remove the valve covers.
  10.  
  11. Disconnect the engine coolant temperature electrical connector.
  12.  
  13. Disconnect the fuel feed line from the fuel rail.
  14.  
  15. Disconnect the fuel injector inline connector.
  16.  
  17. Remove the fuel injector harness connector bracket bolt from the intake manifold.
  18.  
  19. Disconnect the Camshaft Position (CMP) sensor electrical connector.
  20.  
  21. Remove the fuel rail.
  22.  
  23. Remove the lower intake manifold.
  24.  
  25. Loosen the valve rocker arm bolts.
    NOTE
    Place the valve train components in a rack in order to ensure that the components are installed in the same location from which they where removed.

  26.  
  27. Remove the valve rocker arms.
  28.  
  29. Remove the push rods.
    NOTE
    The intake push rods measure 5.81 inches (147.51mm). The exhaust push rods measure 6.1 inches (154.87mm).

  30.  
  31. Remove the lower intake manifold gaskets and seals.
  32.  
  33. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  34.  
  35. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
  36.  
  37. Remove all the loose RTV sealer.
  38.  

To install:


NOTE
Do not use RTV sealer under the lower intake manifold gaskets.

  1. Install the lower intake manifold gaskets and seals.
  2.  
  3. Coat the ends of the push rods using suitable prelube.
  4.  
  5. Install the push rods in their original location.
  6.  
  7. Coat the rocker arm friction surfaces using suitable prelube.
  8.  
  9. Install the valve rocker arms in their original positions.
  10.  
  11. Install the valve rocker arm bolts and tighten to 25 ft. lbs. (34 Nm).
  12.  
  13. With new gaskets and seals in place, apply a small drop of RTV sealer to the 4 corners of the intake manifold to engine block joints.
  14.  
  15. Install the lower intake manifold.
  16.  
  17. Apply sealer to the lower intake manifold bolt threads.
  18.  
  19. Tighten the bolts in sequence as follows:
    1. Tighten bolts 1, 2, 3, and 4 in sequence to 12 ft. lbs. (16 Nm).
    2.  
    3. Tighten bolts 5, 6, 7 and 8 in sequence to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view

      Fig. Lower intake manifold tightening sequence-3.9L engine

    4.  

  20.  
  21. Inspect the fuel rail, fuel injectors and fuel injector O-rings for damage and replace as necessary.
  22.  
  23. Lubricate the fuel injector O-rings.
  24.  
  25. Install the injector nozzles into the lower intake manifold injector bores.
  26.  
  27. Press on the injector rail using the palms of both hands until the injector are fully seated.
  28.  
  29. Install the fuel injector rail bolts and tighten to 89 inch lbs. (10 Nm).
  30.  
  31. Connect the CMP sensor electrical connector.
  32.  
  33. Position the fuel injector harness connector bracket to the intake manifold.
  34.  
  35. Install the fuel injector harness connector bracket bolt.
  36.  
  37. Connect the fuel injector inline connector.
  38.  
  39. Connect the fuel feed line to the fuel rail.
  40.  
  41. Connect the ECT electrical connector.
  42.  
  43. Install the valve covers.
  44.  
  45. Install the upper intake manifold.
  46.  
  47. Install the coolant crossover pipe.
  48.  
  49. Fill the cooling system.
  50.  

Upper Manifold
  1. Drain the cooling system.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the intake manifold cover.
  6.  
  7. Disconnect the fuel feed pipe quick connect fitting from the fuel rail.
  8.  
  9. Disconnect the evaporative (EVAP) emission pipe from the purge solenoid.
  10.  
  11. Open the retaining clip, and remove the fuel and EVAP pipes from the clip.
  12.  
  13. Remove the positive crankcase ventilation (PCV) air tubes.
  14.  
  15. Reposition the brake booster vacuum hose clamp at the intake manifold.
  16.  
  17. Remove the vacuum hose from the intake manifold.
  18.  
  19. Reposition the radiator surge tank inlet hose clamp.
  20.  
  21. Remove the radiator surge tank inlet hose from the inlet pipe.
  22.  
  23. Remove the oil fill neck.
  24.  
  25. Remove the radiator surge tank inlet pipe bolts.
  26.  
  27. Remove the radiator surge tank inlet pipe.
  28.  
  29. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
  30.  
  31. Disconnect the evaporative emission (EVAP) canister purge solenoid electrical connector.
  32.  
  33. Disconnect the electronic throttle control (ETC) electrical connector.
  34.  
  35. Disconnect the inlet manifold valve electrical connector
  36.  
  37. Remove the air cleaner outlet duct.
  38.  
  39. Disconnect the left side spark plug wires from the spark plugs.
  40.  
  41. Disconnect the left side spark plug wires from the ignition coil.
  42.  
  43. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet pipe.
  44.  
  45. Remove the left side spark plug wires.
  46.  
  47. Remove the heater inlet and outlet pipe nuts from the throttle body studs.
  48.  
  49. Remove the inlet and outlet pipe from the studs.
  50.  
  51. Remove the 2 ignition coil bolts.
  52.  
  53. Remove the generator upper bolt, ball stud and rear brace.
  54.  
  55. Remove the upper intake manifold bolts and stud.
  56.  
  57. Separate and remove the upper intake manifold from the lower intake manifold.
  58.  
  59. Remove the upper to lower intake manifold gaskets.
  60.  
  61. Remove the inlet manifold tuning valve bolts and valve.
  62.  
  63. Remove the throttle body bolts/studs and throttle body.
  64.  
  65. Remove the MAP sensor bracket and sensor.
  66.  
  67. Remove the EVAP canister purge solenoid valve bolt and valve.
  68.  
  69. Clean the upper intake to lower intake gasket mating surfaces.
  70.  
  71. Inspect the intake manifold tuning valve seal for damage. The tuning valve blade attachment to the motor should be tight, with no looseness or slack present, Replace as necessary.
  72.  
  73. Apply lubricant to the nose of the tuning valve blade.

    Click image to see an enlarged view

    Fig. Applying lubricant to intake manifold tuning blade-3.9L engine

  74.  

To install:

  1. Inspect the EVAP canister purge solenoid valve seal for damage, replace as necessary.
  2.  
  3. Install the EVAP canister purge solenoid valve and tighten to 12 ft. lbs. (16 Nm).
  4.  
  5. Install the MAP sensor and bracket.
  6.  
  7. Apply threadlock to the throttle body bolts/studs threads and install the throttle body.
  8.  
  9. Install the inlet manifold tuning valve and tighten to 89 inch lbs. (10 Nm).
  10.  
  11. Install new upper-to-lower intake manifold gaskets.
  12.  
  13. Apply threadlock to the upper intake manifold bolts/stud threads.
  14.  
  15. Install the upper intake manifold and tighten the bolts to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Upper intake manifold mounting-3.9L engine

  16.  
  17. Install the alternator.
  18.  
  19. Install the ignition coils.
  20.  
  21. Install the heater inlet and outlet pipes to the throttle body studs.
  22.  
  23. Install the left side spark plug wires.
  24.  
  25. Connect the left side spark plug wires to the spark plugs.
  26.  
  27. Connect the left side spark plug wires to the ignition coil.
  28.  
  29. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet pipe.
  30.  
  31. Install the air cleaner outlet duct.
  32.  
  33. Connect the inlet manifold valve electrical connector.
  34.  
  35. Connect the electronic throttle control (ETC) electrical connector.
  36.  
  37. Connect the evaporative emission (EVAP) canister purge solenoid electrical connector.
  38.  
  39. Connect the manifold absolute pressure (MAP) sensor electrical connector.
  40.  
  41. Install the radiator surge tank inlet pipe.
  42.  
  43. Install the radiator surge tank inlet pipe bolts.
  44.  
  45. Install the oil fill neck.
  46.  
  47. Install the radiator surge tank inlet hose to the inlet pipe.
  48.  
  49. Position the radiator surge tank inlet hose clamp.
  50.  
  51. Install the vacuum hose to the intake manifold.
  52.  
  53. Position the brake booster vacuum hose clamp at the intake manifold.
  54.  
  55. Install the positive crankcase ventilation (PCV) air tubes.
  56.  
  57. Install the fuel and EVAP pipes to the retaining clip.
  58.  
  59. Connect the evaporative (EVAP) emission pipe to the purge solenoid.
  60.  
  61. Connect the fuel feed pipe quick connect fitting to the fuel rail.
  62.  
  63. Remove the intake manifold cover.
  64.  
  65. Fill the cooling system.
  66.  

 
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