Mitsubishi Montero, Sport 1998-06

Intake Manifold

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Relieve the fuel pressure.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Upper radiator hose from the thermostat housing
     
    Air intake hoses, breather hose and the air intake pipe
     
    Wires, hoses and linkages from the throttle body
     
    Ignition coil
     
    Brake booster hose and vacuum hose cluster from the air intake plenum
     
    Air intake plenum from the intake manifold
     
    Fuel lines, keep the line covered or plugged
     
    Fuel rail assembly with injectors intact
     
    Heater hose from the manifold
     
    Engine Coolant Temperature (ECT) sensor
     
    Water outlet fitting
     
    Distributor, matchmark for reassembly
     
    Intake manifold from the cylinder head and engine
     
    Manifold Differential Pressure (MDP) sensor, if equipped
     

  8.  
  9. Clean and dry the mating surfaces of the manifold and cylinder head.
  10.  

To install:

  1. Install or connect the following:

    New gasket and the intake manifold to the head. Starting from the middle and working outward, tighten the retaining nuts to 14 ft. lbs. (19 Nm).
     
    ECT sensor
     
    Water outlet fitting. Torque the bolts to 14 ft. lbs. (19 Nm).
     
    Distributor with matchmarks aligned
     
    Fuel rail assembly to the manifold using a new O-ring
     
    Fuel lines
     
    Heater hose to the manifold
     
    Air intake plenum with a new gasket. Tighten the retaining bolts to 12 ft. lbs. (16 Nm).
     
    Vacuum hoses cluster, brake booster hose and all wires, hoses and linkages to the throttle body
     
    Ignition coil
     
    Air intake hoses, breather hose and the air intake pipe
     
    Manifold Differential Pressure (MDP) sensor, if equipped
     
    Upper radiator hose
     
    Negative battery cable
     

  2.  
  3. Refill the radiator with coolant.
  4.  
  5. Check the system for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the intake plenum chamber and related components-2.4L engine shown



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold and related components-2.4L engine shown

  6.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel pressure.
  4.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Drain the engine coolant.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     

  4.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



Air intake hose from the throttle body
 
Positive Crankcase Ventilation (PCV) hose
 
Exhaust Gas Recirculation (EGR) valve
 
Manifold Differential Pressure (MDP) sensor
 
Vacuum hoses from the throttle body and air intake plenum
 
Accelerator cable and the throttle control cable
 
Coolant hoses
 
Engine oil filler neck bracket from the air intake plenum
 
EGR tube from the air intake plenum
 
Plenum brackets
 
Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed.
 
Fuel hose from the fuel rail
 
Fuel return line and vacuum hose from the fuel pressure regulator
 
Electrical connectors from the injectors
 
Fuel rail and injectors
 
Intake manifold
 

  1. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.
  2.  

To install:

  1. Install or connect the following:

    Intake manifold. Torque the nuts to 16 ft. lbs. (21 Nm) start from the center and working outward.
     

  2.  
  3. Connect the hoses and connect the wires to the coolant switches.

    Fuel rail assembly and connect the fuel hoses
     
    New gasket and the air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. lbs. (17 Nm).
     
    Plenum brackets
     
    PCV hose and vacuum hose cluster to the plenum
     
    EGR tube
     
    EGR temperature sensor wire
     
    Wires, hoses and linkages to the throttle body
     
    Air intake hose to the throttle body
     
    Upper radiator hose to the thermostat housing
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant.
  6.  
  7. Check fuel system for leaks.
  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the upper intake manifold and related components-3.0L 24-valve engine shown



    Click image to see an enlarged view

    Fig. Exploded view of the lower intake manifold and related components-3.0L 24-valve engine shown


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Air intake hose from the throttle body
     
    Positive Crankcase Ventilation (PCV) hose
     
    Exhaust Gas Recirculation (EGR) valve
     
    Manifold Differential Pressure (MDP) sensor
     
    Vacuum hoses from the throttle body and air intake plenum
     
    Accelerator cable and the throttle control cable
     
    Coolant hoses
     
    Engine oil filler neck bracket from the air intake plenum
     
    EGR tube from the air intake plenum
     
    Plenum brackets
     
    Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed.
     
    Fuel hose from the fuel rail
     
    Fuel return line and vacuum hose from the fuel pressure regulator
     
    Electrical connectors from the injectors
     
    Fuel rail and injectors
     
    Intake manifold
     

  8.  
  9. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.
  10.  

To install:

  1. Install or connect the following:

    Intake manifold. Torque the nuts to 16 ft. lbs. (21 Nm) start from the center and working outward.
     

  2.  
  3. Connect the hoses and connect the wires to the coolant switches.

    Fuel rail assembly and connect the fuel hoses
     
    New gasket and the air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. lbs. (17 Nm).
     
    Plenum brackets
     
    PCV hose and vacuum hose cluster to the plenum
     
    EGR tube
     
    EGR temperature sensor wire
     
    Wires, hoses and linkages to the throttle body
     
    Air intake hose to the throttle body
     
    Upper radiator hose to the thermostat housing
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant.
  6.  
  7. Check fuel system for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the upper intake manifold and related components-3.0L 24-valve engine shown



    Click image to see an enlarged view

    Fig. Exploded view of the lower intake manifold and related components-3.0L 24-valve engine shown

  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.



    Negative battery cable
     



    Air intake hose from the throttle body
     
    Positive Crankcase Ventilation (PCV) hose
     
    Exhaust Gas Recirculation (EGR) valve
     
    Manifold Differential Pressure (MDP) sensor
     
    Vacuum hoses from the throttle body and air intake plenum
     
    Accelerator cable and the throttle control cable
     
    Coolant hoses
     
    Engine oil filler neck bracket from the air intake plenum
     
    EGR tube from the air intake plenum
     
    Plenum brackets
     
    Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed.
     
    Fuel hose from the fuel rail
     
    Fuel return line and vacuum hose from the fuel pressure regulator
     
    Electrical connectors from the injectors
     
    Fuel rail and injectors
     
    Intake manifold
     

  8.  
  9. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.
  10.  

To install:

  1. Install or connect the following:

    Intake manifold. Torque the nuts to 16 ft. lbs. (21 Nm) start from the center and working outward.
     

  2.  
  3. Connect the hoses and connect the wires to the coolant switches.

    Fuel rail assembly and connect the fuel hoses
     
    New gasket and the air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. lbs. (17 Nm).
     
    Plenum brackets
     
    PCV hose and vacuum hose cluster to the plenum
     
    EGR tube
     
    EGR temperature sensor wire
     
    Wires, hoses and linkages to the throttle body
     
    Air intake hose to the throttle body
     
    Upper radiator hose to the thermostat housing
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant.
  6.  
  7. Check fuel system for leaks.

    Click image to see an enlarged view

    Fig. Upper intake manifold and related components-3.0L engine



    Click image to see an enlarged view

    Fig. Lower intake manifold and related components-3.0L engine

  8.  

12-Valve
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Remove or disconnect the following:

    Injector and fuel rail
     
    Insulator
     
    Fuel pressure regulator
     
    O-ring
     
    Insulator
     
    Injector
     
    O-ring
     
    Gromet
     
    Fuel rail
     
    Water hose A
     
    Water hose B
     
    Heat pipe
     
    Heat pipe gasket
     
    Water hose
     
    Engine coolant temperature gauge unit
     
    Water outlet fitting
     
    Water outlet fitting gasket
     
    Thermostat
     
    Intake manifold
     
    Intake manifold gasket

    Click image to see an enlarged view

    Fig. Removing and installing intake manifold 3.0L 12V (1996)

     

  6.  

To install:

Reverse removal procedure to install. Note the following steps during installation.

  1. When installing engine coolant temperature sensor, use 3M Nut Locking No. 4171 or equivalent.
  2.  
  3. When installing engine coolant temperature gauge unit, use 3M Part No. 8660 or equivalent.
  4.  
  5. Before installing the injector, the rubber o-ring must be lubricated with a drop of new engine oil for easy installation. Insert the injector top end into the fuel rail. Be careful not to damage the o-ring during installation.
    CAUTION
    Use care not to let the engine oil enter the fuel rail.

  6.  
  7. Before installing the fuel pressure regulator, the o-ring must be lubricated with a drop of the new engine oil for easy installation.
    CAUTION
    Use care not to let the engine oil enter the fuel rail.

  8.  

24-Valve
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Remove or disconnect the following:

    Engine coolant temperature gauge unit
     
    Engine coolant temperature sensor
     
    Water outlet fitting
     
    Water outlet fitting gasket
     
    Water hose
     
    Water outlet pipe
     
    O-ring
     
    Water hose
     
    Water inlet fitting
     
    Thermostat
     
    Thermostat case
     
    Thermostat case gasket
     
    Water passage
     
    Gasket
     
    Water pipe
     
    O-ring
     
    Water hose
     
    Water hose

    Click image to see an enlarged view

    Fig. Removing and installing intake manifold 3.0L 24V (1996) 1 of 2

     
    Injector harness
     
    Injector and fuel rail
     
    Insulator
     
    Fuel pressure regulator
     
    O-ring
     
    Insulator
     
    Injector
     
    O-ring
     
    Grommet
     
    Fuel pipe
     
    O-ring
     
    Fuel rail
     
    Intake manifold
     
    Intake manifold gasket

    Click image to see an enlarged view

    Fig. Removing and installing intake manifold 3.0L 24V (1996) 2 of 2

     

  6.  

To install:

Reverse the removal procedures to install. Take note of the following installation service points.

  1. When installing the intake manifold:
    1. Tighten the nuts on the right bank to 3.7-5.9 ft. lbs. (5-8 Nm).
    2.  
    3. Tighten the nuts on the left bank to 16 ft. lbs. (21 Nm). Then tighten the nuts on the right bank to 16 ft. lbs (21 Nm).
    4.  
    5. Tighten the nuts on the left bank and those on the right bank again in that order.
    6.  

  2.  
  3. When installing the injector:
    1. Before installing the injector, the rubber o-ring must be lubricated with a drop of new engine oil for easy installation.
      CAUTION
      Use care not to let the engine oil enter the fuel rail.

    2.  
    3. Insert the injector top end into the fuel rail. Be careful not to damage the O-ring during installation.
    4.  

  4.  
  5. When installing the fuel pressure regulator:
    1. Before installing the pressure regulator, the O-ring must be lubricated with a drop of new engine oil for easy installation.
      CAUTION
      Use care not to let the engine oil enter the fuel rail.

    2.  

  6.  
  7. When installing the O-ring and water pipe:
    1. Wet the O-ring (with water) to facilitate assembly.
      CAUTION
      Keep the O-ring free of oil or grease.

    2.  

  8.  
  9. When installing the thermostat, install in the thermostat case with its jiggle valve located at the top position.
  10.  
  11. When installing the engine coolant temperature sensor, use 3M Nut Locking No. 4171 or equivalent.
  12.  
  13. When installing the engine coolant temperature gauge unit, use 3M Part No. 8660 or equivalent.
  14.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     

  6.  


CAUTION
Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



Air intake hose from the throttle body
 
Electrical connectors and vacuum hoses from the throttle body and air intake plenum
 
Accelerator cable and the throttle control cable
 
Coolant hoses
 
Positive Crankcase Ventilation (PCV) hose
 
Exhaust Gas Recirculation (EGR) temperature sensor connector
 
EGR tube from the air intake plenum
 
Intake manifold plenum cover
 
Intake manifold plenum stay brackets
 
Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed
 
Induction control valve assembly
 
Fuel hose from the fuel rail
 
Fuel return line and vacuum hose from the fuel pressure regulator
 
Electrical connectors from the injectors
 
Fuel rail and injectors
 
Intake manifold
 

  1. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.
  2.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the nuts to 16 ft. lbs. (21 Nm). Start from the center and work outward.
     
    Fuel rail assembly and connect the fuel hoses
     
    Induction control valve assembly and tighten to 72 inch lbs. (9 Nm).
     
    New gasket and air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. lbs. (18 Nm).
     
    Plenum to engine brackets
     
    Hoses and wires to the coolant switches
     
    PCV hose and vacuum hose cluster to the plenum
     
    EGR tube. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    EGR temperature sensor wire
     
    Wires, hoses and linkages to the throttle body
     
    Air intake hose to the throttle body
     
    Upper radiator hose to the thermostat housing
     
    Negative battery cable
     

  2.  
  3. Refill the radiator with coolant.
  4.  
  5. Check the system for fuel leaks.
  6.  
  7. Set all adjustments to specifications.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Partially drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Air intake hose from the throttle body
     
    Electrical connectors and vacuum hoses from the throttle body and air intake plenum
     
    Accelerator cable and the throttle control cable
     
    Coolant hoses
     
    Positive Crankcase Ventilation (PCV) hose
     
    Exhaust Gas Recirculation (EGR) temperature sensor connector
     
    EGR tube from the air intake plenum
     
    Intake manifold plenum cover
     
    Intake manifold plenum stay brackets
     
    Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed
     
    Induction control valve assembly
     
    Fuel hose from the fuel rail
     
    Fuel return line and vacuum hose from the fuel pressure regulator
     
    Electrical connectors from the injectors
     
    Fuel rail and injectors
     
    Intake manifold
     

  8.  
  9. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.
  10.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the nuts to 16 ft. lbs. (21 Nm). Start from the center and work outward.
     
    Fuel rail assembly and connect the fuel hoses
     
    Induction control valve assembly and tighten to 72 inch lbs. (9 Nm).
     
    New gasket and air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. lbs. (18 Nm).
     
    Plenum to engine brackets
     
    Hoses and wires to the coolant switches
     
    PCV hose and vacuum hose cluster to the plenum
     
    EGR tube. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    EGR temperature sensor wire
     
    Wires, hoses and linkages to the throttle body
     
    Air intake hose to the throttle body
     
    Upper radiator hose to the thermostat housing
     
    Negative battery cable
     

  2.  
  3. Refill the radiator with coolant.
  4.  
  5. Check the system for fuel leaks.
  6.  
  7. Set all adjustments to specifications.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Partially drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Air intake hose from the throttle body
     
    Electrical connectors and vacuum hoses from the throttle body and air intake plenum
     
    Accelerator cable and the throttle control cable
     
    Coolant hoses
     
    Positive Crankcase Ventilation (PCV) hose
     
    Exhaust Gas Recirculation (EGR) temperature sensor connector
     
    EGR tube from the air intake plenum
     
    Intake manifold plenum cover
     
    Intake manifold plenum stay brackets
     
    Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed
     
    Induction control valve assembly
     
    Fuel hose from the fuel rail
     
    Fuel return line and vacuum hose from the fuel pressure regulator
     
    Electrical connectors from the injectors
     
    Fuel rail and injectors
     
    Intake manifold
     

  8.  
  9. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.
  10.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the nuts to 16 ft. lbs. (21 Nm). Start from the center and work outward.
     
    Fuel rail assembly and connect the fuel hoses
     
    Induction control valve assembly and tighten to 72 inch lbs. (9 Nm).
     
    New gasket and air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. lbs. (18 Nm).
     
    Plenum to engine brackets
     
    Hoses and wires to the coolant switches
     
    PCV hose and vacuum hose cluster to the plenum
     
    EGR tube. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    EGR temperature sensor wire
     
    Wires, hoses and linkages to the throttle body
     
    Air intake hose to the throttle body
     
    Upper radiator hose to the thermostat housing
     
    Negative battery cable
     

  2.  
  3. Refill the radiator with coolant.
  4.  
  5. Check the system for fuel leaks.
  6.  
  7. Set all adjustments to specifications.
  8.  

3.8L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     

  6.  


CAUTION
Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



Throttle body
 
Exhaust Gas Recirculation (EGR) valve connector
 
Evaporative emission (EVAP) purge solenoid valve connector
 
Right bank Heated Oxygen Sensor (HO2S) connector connection
 
Manifold Differential Pressure (MDP) sensor connector
 
Capacitor connector
 
Knock Sensor (KS) connector
 
Control wiring harness and Camshaft Position (CMP) sensor wiring harness combination connector
 
Ground cable
 
Fuel injector connector
 
Control wiring harness and injector wiring harness combination connector
 
Intake manifold tuning solenoid connector
 
Engine Coolant Temperature (ECT) sensor connector
 
ECT gauge unit connector
 
Crankshaft Position (CKP) sensor connector
 
Ground cable
 
Knock Sensor (KS) and Camshaft Position (CMP) sensor combination connector
 
Control wiring harness and injector harness combination connector
 
Connector bracket
 
Positive Crankcase Ventilation (PCV) hose connection
 
Fuel pipe
 
Vacuum hose connection
 
Water outlet fitting bracket
 
EGR pipe
 
EGR pipe and gasket
 
Intake manifold plenum stay
 
Right bank HO2S connector
 
Fuel pipe clip
 
Intake manifold plenum
 
Intake manifold plenum gasket
 
Manifold Differential Pressure (MDP) sensor and O-ring
 
Solenoid valve and vacuum hose assembly
 
Capacitor
 
EGR valve and gasket
 
Purge hose
 
EVAP purge solenoid valve
 
Intake manifold tuning valve assembly
 
Intake manifold tuning valve gaskets P and S
 
High pressure fuel hose connection and O-ring
 
Fuel pressure regulator and O-ring
 
Fuel injector connectors
 
Fuel rail (with injectors attached)
 
Insulators
 
Water hose connection
 
Intake manifold retainers, manifold and gasket. Thoroughly clean and dry the mating surfaces of the manifold and heads.
 



Click image to see an enlarged view

Fig. Exploded view of the intake manifold-3.8L engine

To install:

  1. Install or connect the following:

    New intake manifold gasket. Make sure the gaskets are installed with the protrusions as shown in the illustration.
     


    Click image to see an enlarged view

    Fig. The intake manifold gaskets must be installed properly-3.8L engine

    Intake manifold
     

  2.  
  3. Install the intake manifold bolts and tighten as follows:
    1. 1st step: Right bank nuts to 58 inch lbs. (6.5 Nm).
    2.  
    3. 2nd step: Left bank nuts to 16 ft. lbs. (22 Nm).
    4.  
    5. 3rd step: Right bank nuts to 16 ft. lbs. (22 Nm).
    6.  
    7. 4th step: Left bank nuts to 16 ft. lbs. (22 Nm).
    8.  
    9. 5th step: Right bank nuts to 16 ft. lbs. (22 Nm).
    10.  



    Click image to see an enlarged view

    Fig. Left and right bank nut locations-3.8L engine



    Water hose connection
     
    Insulators
     
    Fuel rail and injector assembly
     
    Fuel injector connectors
     
    Fuel pressure regulator and O-ring
     
    High pressure fuel hose connection and O-ring
     
    Intake manifold tuning valve gaskets P and S
     
    Intake manifold tuning valve assembly
     
    EVAP purge solenoid valve
     
    Purge hose
     
    EGR valve and gasket
     
    Capacitor
     
    Solenoid valve and vacuum hose assembly
     
    Manifold Differential Pressure (MDP) sensor and O-ring
     
    Intake manifold plenum gasket
     


    Click image to see an enlarged view

    Fig. Proper installation of the intake manifold plenum gasket-3.8L engine

    Intake manifold plenum
     
    Fuel pipe clip
     
    Right bank HO2S connector
     
    Intake manifold plenum stay
     
    EGR pipe and gasket
     
    EGR pipe
     
    Water outlet fitting bracket
     
    Vacuum hose connection
     
    Fuel pipe
     
    PCV hose connection
     
    Connector bracket
     
    Control wiring harness and injector harness combination connector
     
    KS and CMP sensor combination connector
     
    Ground cable
     
    CKP sensor connector
     
    ECT gauge unit connector
     
    ECT sensor connector
     
    Intake manifold tuning solenoid connector
     
    Control wiring harness and injector wiring harness combination connector
     
    Fuel injector connector
     
    Ground cable
     
    Control wiring harness and CMP sensor wiring harness combination connector
     
    KS connector
     
    Capacitor connector
     
    MDP sensor connector
     
    Right bank HO2S connector
     
    EVAP purge solenoid valve connector
     
    EGR valve connector
     
    Throttle body
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant.
  6.  
  7. Check the system for fuel leaks.
  8.  
  9. Set all adjustments to specifications.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Partially drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Throttle body
     
    Exhaust Gas Recirculation (EGR) valve connector
     
    Evaporative emission (EVAP) purge solenoid valve connector
     
    Right bank Heated Oxygen Sensor (HO 2 S) connector connection
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Capacitor connector
     
    Knock Sensor (KS) connector
     
    Control wiring harness and Camshaft Position (CMP) sensor wiring harness combination connector
     
    Ground cable
     
    Fuel injector connector
     
    Control wiring harness and injector wiring harness combination connector
     
    Intake manifold tuning solenoid connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    ECT gauge unit connector
     
    Crankshaft Position (CKP) sensor connector
     
    Ground cable
     
    Knock Sensor (KS) and Camshaft Position (CMP) sensor combination connector
     
    Control wiring harness and injector harness combination connector
     
    Connector bracket
     
    Positive Crankcase Ventilation (PCV) hose connection
     
    Fuel pipe
     
    Vacuum hose connection
     
    Water outlet fitting bracket
     
    EGR pipe
     
    EGR pipe and gasket
     
    Intake manifold plenum stay
     
    Right bank HO 2 S connector
     
    Fuel pipe clip
     
    Intake manifold plenum
     
    Intake manifold plenum gasket
     
    Manifold Differential Pressure (MDP) sensor and O-ring
     
    Solenoid valve and vacuum hose assembly
     
    Capacitor
     
    EGR valve and gasket
     
    Purge hose
     
    EVAP purge solenoid valve
     
    Intake manifold tuning valve assembly
     
    Intake manifold tuning valve gaskets P and S
     
    High pressure fuel hose connection and O-ring
     
    Fuel pressure regulator and O-ring
     
    Fuel injector connectors
     
    Fuel rail (with injectors attached)
     
    Insulators
     
    Water hose connection
     
    Intake manifold retainers, manifold and gasket. Thoroughly clean and dry the mating surfaces of the manifold and heads.

    Click image to see an enlarged view

    Fig. Intake manifold and related components-3.8L engine

     

  8.  

To install:

  1. Install or connect the following:

    New intake manifold gasket. Make sure the gaskets are installed with the protrusions as shown in the illustration.

    Click image to see an enlarged view

    Fig. Intake manifold gasket positioning-3.8L engine

     
    Intake manifold
     

  2.  
  3. Install the intake manifold nuts and torque to specification.

    Click image to see an enlarged view

    Fig. Intake manifold retaining nut locations-3.8L engine



    Water hose connection
     
    Insulators
     
    Fuel rail and injector assembly
     
    Fuel injector connectors
     
    Fuel pressure regulator and O-ring
     
    High pressure fuel hose connection and O-ring
     
    Intake manifold tuning valve gaskets P and S
     
    Intake manifold tuning valve assembly
     
    EVAP purge solenoid valve
     
    Purge hose
     
    EGR valve and gasket
     
    Capacitor
     
    Solenoid valve and vacuum hose assembly
     
    Manifold Differential Pressure (MDP) sensor and O-ring
     
    Intake manifold plenum gasket

    Click image to see an enlarged view

    Fig. Proper installation of the intake manifold plenum gasket-3.8L engine

     
    Intake manifold plenum
     
    Fuel pipe clip
     
    Right bank HO 2 S connector
     
    Intake manifold plenum stay
     
    EGR pipe and gasket
     
    EGR pipe
     
    Water outlet fitting bracket
     
    Vacuum hose connection
     
    Fuel pipe
     
    PCV hose connection
     
    Connector bracket
     
    Control wiring harness and injector harness combination connector
     
    KS and CMP sensor combination connector
     
    Ground cable
     
    CKP sensor connector
     
    ECT gauge unit connector
     
    ECT sensor connector
     
    Intake manifold tuning solenoid connector
     
    Control wiring harness and injector wiring harness combination connector
     
    Fuel injector connector
     
    Ground cable
     
    Control wiring harness and CMP sensor wiring harness combination connector
     
    KS connector
     
    Capacitor connector
     
    MDP sensor connector
     
    Right bank HO 2 S connector
     
    EVAP purge solenoid valve connector
     
    EGR valve connector
     
    Throttle body
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant.
  6.  
  7. Check the system for fuel leaks.
  8.  
  9. Set all adjustments to specifications.
  10.  

 
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