Montana, Silhouette, Venture 2000-2005

Upper Intake Manifold (Plenum)

Print

Removal & Installation



This engine uses a 2-piece intake manifold. The upper half (often called a plenum) mounts the throttle body. The lower half of the manifold bolts to the engine and contains the fuel injectors. Please note that this engine uses a sequential multi-port fuel injection system. Injector connectors must be connected to their appropriate fuel injector assembly or engine emissions and engine performance will be seriously affected. Identify and tag for identification all wiring connectors as well as vacuum and other components as required to assure correct assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine coolant. Remove the coolant recovery bottle.
  4.  
  5. Relieve the fuel system pressure using the recommended procedure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air inlet duct
     
    Accelerator and cruise control cables and bracket from the throttle body
     
    Throttle Position (TP) sensor connector from the throttle body
     
    Idle Air Control (IAC) valve connector from the throttle body
     
    Left side spark plug wires
     
    Left side spark plug wire harness clip and harness
     
    Throttle body heater hoses
     
    Evaporative emissions (EVAP) canister purge solenoid valve vacuum hoses
     
    EVAP canister purge solenoid valve
     
    Ignition coil bracket and coils
     
    Wire harness for the Manifold Air Pressure (MAP) sensor and upper intake manifold
     
    Emissions control vacuum harness
     
    Brake booster vacuum hose from the upper intake manifold
     
    Vacuum hose connection for the Heater Vent Air Conditioning (HVAC) source hose
     
    Vacuum hose connection for the fuel pressure regulator
     
    Exhaust Gas Recirculation (EGR) valve
     
    MAP sensor and bracket
     
    Upper intake manifold
     
    Upper intake manifold gasket
     
    Throttle body, if replacing the manifold

    Click image to see an enlarged view

    Fig. Remove upper intake manifold

     

  8.  

To install:

  1. Clean all parts well. Use care in cleaning old gasket material from the machined aluminum surfaces on the plenum and manifold as sharp tools may damage sealing surfaces.
  2.  
  3. Clean the mating surfaces to the upper intake manifold and engine block. Remove any loose pieces of RTV sealer.
  4.  
  5. Install or connect the following:

    Throttle body to the upper intake manifold (if removed). Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Upper intake manifold gasket
     
    Upper intake manifold
     
    MAP sensor and bracket. Torque the bolt to 44 inch lbs. (5 Nm).
     
    Upper intake manifold bolts. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    EGR valve. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    HVAC vacuum source hose to the upper intake manifold
     
    Fuel pressure regulator vacuum hose to the upper intake manifold
     
    Brake booster vacuum hose
     
    MAP sensor and bracket. Torque the bolt to 44 inch lbs. (5 Nm).
     
    Emissions control vacuum harness
     
    Vacuum hose for the MAP sensor
     
    Wiring harness to the MAP sensor
     
    Ignition coil bracket and coils. Torque the fasteners to 18 ft. lbs. (25 Nm).
     
    EVAP canister purge solenoid valve
     
    Vacuum hoses to the EVAP canister purge solenoid valve
     
    Throttle body heater hose
     
    Left side spark plug wire harness clip
     
    Spark plugs wires
     
    TP sensor wire harness connector to the throttle body
     
    IAC valve wire harness connector to the throttle body
     
    Accelerator and cruise control cables and bracket to the throttle body. Torque the fasteners to 106 inch lbs. (12 Nm).
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  6.  
  7. Fill the coolant system.
  8.  
  9. Fill the engine with new oil.
  10.  
  11. Turn the ignition to the ON position several times to pressurize the fuel system.
  12.  
  13. Start the engine and check for any leakage and repair if necessary.
  14.  
  15. Check and top off all fluid levels if needed.
  16.  

 
label.common.footer.alt.autozoneLogo