Rendezvous 2006-2007

Intake Manifold

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Removal & Installation



3.4L Engine
Lower
  1. Remove the upper intake manifold.
  2.  
  3. Remove the engine left side valve rocker arm cover.
  4.  
  5. Remove the engine right side valve rocker arm cover.
  6.  
  7. Disconnect the wiring harness from the engine coolant temperature (ECT) sensor.
    NOTE
    Use masking tape or another appropriate method in order to identify each fuel injector wiring harness connector cylinder number.

  8.  
  9. Disconnect and remove the fuel injector, manifold air pressure (MAP) and ECT wiring harness.
  10.  
  11. Remove the fuel feed and return pipe from the fuel injector rail.
  12.  
  13. Remove the fuel feed and return pipe retaining clip bolt.
  14.  
  15. Remove the fuel feed and return pipe retaining clip.
  16.  
  17. Remove the fuel injector rail bolts.
  18.  
  19. Remove the fuel injector rail with the fuel injectors.
    NOTE
    Do NOT disconnect the power steering pipes or hoses from the power steering pump.

  20.  
  21. Remove the power steering pump from the front engine cover and reposition.
  22.  
  23. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition.
  24.  
  25. Disconnect the inlet radiator hose from the engine.
  26.  
  27. Disconnect the thermostat bypass hose from the lower intake manifold pipe.
  28.  
  29. Remove the lower intake manifold bolts.
  30.  
  31. Remove the lower intake manifold.
  32.  
  33. Loosen the valve rocker arms and remove the push rods.
  34.  
  35. Remove the lower intake manifold gaskets and seals.
  36.  
  37. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  38.  
  39. Clean and inspect the lower intake manifold.
  40.  
  41. If you are replacing the lower intake manifold, perform the following steps:
    1. Remove the ECT sensor.
    2.  
    3. Remove the thermostat.
    4.  

  42.  

To install:

If you are replacing the lower intake manifold, perform the following steps.

  1. Install the ECT sensor.
  2.  
  3. Install the thermostat.
    NOTE
    All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139 (Canadian P/N 10953463), or equivalent, to clean the surfaces.

  4.  
  5. Install the lower intake manifold gaskets.
  6.  
  7. Install the push rods and tighten the valve rocker arms.
  8.  
  9. With the gaskets in place apply a small drop 8-10 mm (0.31-0.39 in.) of RTV sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the 4 corners of the intake manifold to block joint.
  10.  
  11. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in.) wide and 3.0-5.0 mm (0.12-0.20 in.) thick.
  12.  
  13. Install the lower intake manifold.
  14.  
  15. Apply sealer GM P/N 12345382, (Canadian P/N 10953489) or the equivalent to the lower intake manifold bolt threads.
    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
    All lower intake manifold bolts need to be cleaned, free of any foreign material, and reused only if new bolts are unavailable. Use GM P/N 12345382 (Canadian P/N 10953489) or equivalent and apply to the old intake manifold bolt threads.


    WARNING
    The manufacturer recommends the center bolts be fully torqued before the diagonal bolts to assure proper seal ability.


    NOTE
    Lower intake manifold bolts in location 6 and 7 should be torqued to specification using a crow-s foot type tool.

  16.  
  17. Install the lower intake manifold bolts.
  18.  
  19. Tighten the lower intake manifold bolts in sequence to 62 inch lbs. (7 Nm) on the first pass.
  20.  
  21. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 15 ft. lbs. (20 Nm) on the final pass.
  22.  
  23. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 18 ft. lbs. (25 Nm) on the final pass.

    Click image to see an enlarged view

    Fig. Lower intake manifold torque sequence-3.4L and 3.5L Engines

  24.  
  25. Connect the thermostat bypass hose to the lower intake manifold pipe.
  26.  
  27. Connect the inlet radiator hose to the engine.
  28.  
  29. Connect the heater inlet pipe to the lower intake manifold.
  30.  
  31. Install the power steering pump to the front engine cover.
  32.  
  33. Install the fuel injector rail.
  34.  
  35. Connect the fuel feed and return pipe to the fuel injector rail.
  36.  
  37. Install the fuel feed and return pipe retaining clip.
  38.  
  39. Install the fuel feed and return pipe retaining clip bolt. Tighten the fuel feed and return pipe retaining clip bolt to 71 inch lbs. (8 Nm).
    NOTE
    The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.

  40.  
  41. Install and connect the fuel injector, MAP and ECT wiring harness.
  42.  
  43. Install the wiring harness to the ECT sensor.
  44.  
  45. Install the engine right side valve rocker arm cover.
  46.  
  47. Install the engine left side valve rocker arm cover.
  48.  
  49. Install the upper intake manifold.
  50.  

Upper

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
     
    Vacuum harness from the 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
     
    Alternator through-bolt bracket
     
    Upper intake manifold
     
    Upper intake manifold gasket
     
    Throttle body, if replacing the manifold

    Click image to see an enlarged view

    Fig. Removing the upper intake manifold-3.4L engine

     

  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 and upper intake manifold
     
    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 hoses
     
    Left side spark plug wire harness clip
     
    Spark plugs wires
     
    TP sensor wire harness connector to the throttle body
     
    IAV 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.  

3.5L Engine
Lower Manifold

WARNING
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 left and right valve rocker arm covers.
  4.  
  5. Remove the fuel injector rail.
  6.  
  7. Reposition the radiator inlet hose clamp at the thermostat housing.
  8.  
  9. Remove the radiator inlet hose from the thermostat housing.
  10.  
  11. Disconnect the heater inlet hose quick connect.
  12.  
  13. Remove the heater inlet pipe nut.
  14.  
  15. Remove the heater inlet pipe from the lower intake manifold.
  16.  
  17. Remove the lower intake manifold bolts.
  18.  
  19. Remove the lower intake manifold.
  20.  
  21. Remove the valve rocker arms and pushrods.
  22.  
  23. Remove the lower intake manifold gaskets and seals.
  24.  
  25. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
  26.  
  27. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
  28.  
  29. Remove all the loose room temperature vulcanizing (RTV) sealer.
  30.  
  31. If replacing the lower intake manifold perform the following steps. If not, proceed to the installation of the lower intake manifold gaskets and seals (below).
  32.  
  33. Remove the thermostat housing bolts and housing.
  34.  
  35. Remove the thermostat.
  36.  

To install:


NOTE
All gasket-mating surfaces need to be free of oil and foreign material.

  1. If the lower intake manifold was replaced, perform the following steps. If not, proceed to the installation of the lower intake manifold gaskets and seals (below).
  2.  
  3. Install the thermostat.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4.  
  5. Install the thermostat housing and bolts and tighten the bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the lower intake manifold gaskets and seals.
  8.  
  9. Install the valve rocker arms and pushrods.
  10.  
  11. Apply a small drop 0.31-0.39 in (8-10 mm) of RTV sealer, GM P/N 12378521 (Canadian P/N 88901148) to the 4 corners of the intake manifold to block joints.
  12.  
  13. Install the lower intake manifold.
    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.

  14.  
  15. Install NEW lower intake manifold bolts, if the bolts do not have the thread locking patch then apply sealer GM P/N to12345382 (Canadian P/N 10953489) the lower intake manifold bolt threads.
    NOTE
    Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.



    Click image to see an enlarged view

    Fig. Intake manifold torque sequence

  16.  
  17. Tighten the lower intake manifold bolts:
    1. Tighten the bolts on the first pass in sequence to 115 inch lbs. (13 Nm).
    2.  
    3. Tighten the bolts (1, 2, 3, 4) on the second pass in sequence to 15 ft. lbs. (20 Nm).
    4.  
    5. Tighten the bolts (5, 6, 7, 8) on the final pass in sequence to 18 ft. lbs. (25 Nm).
    6.  

  18.  
  19. Install the heater inlet pipe to the lower intake manifold.
  20.  
  21. Install the heater inlet pipe nut and tighten the nut to 18 ft. lbs. (25 Nm).
  22.  
  23. Connect the heater inlet hose quick connect.
  24.  
  25. Install the radiator inlet hose to the thermostat housing.
  26.  
  27. Position the radiator inlet hose clamp at the thermostat housing.
  28.  
  29. Install the fuel injector rail.
  30.  
  31. Install the left and right valve rocker arm covers.
  32.  
  33. Install the upper intake manifold.
  34.  

Upper Manifold
  1. Drain the cooling system.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the Evaporative Emission (EVAP) canister purge solenoid valve quick connect fitting.
  8.  
  9. Remove the Positive Crankcase Ventilation (PCV) fresh air tube from the rocker cover.
  10.  
  11. Reposition the brake booster vacuum hose clamp at the intake manifold.
  12.  
  13. Remove the brake booster vacuum hose from the intake manifold.
  14.  
  15. Disconnect the electronic control module electrical connector.
  16.  
  17. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
  18.  
  19. Remove the engine harness clip from PCV foul air clip.
  20.  
  21. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical connector.
  22.  
  23. Disconnect the EVAP canister purge solenoid valve electrical connector.
  24.  
  25. Remove the engine harness clips from the intake manifold.
  26.  
  27. Disconnect the spark plug wires from the ignition coil.
  28.  
  29. Remove spark plug wire harness clips from the following:

    Ignition coil bracket
     
    Spark plug wire support
     
    Coolant bypass pipe
     

  30.  
  31. Disconnect the spark plug wires from the spark plugs.
  32.  
  33. Remove the PCV foul air tube bolt.
  34.  
  35. Remove the PCV foul air tube clip.
  36.  
  37. Remove the PCV foul air tube.
  38.  
  39. Remove the thermostat bypass pipe.
  40.  
  41. Remove the ignition coil.
  42.  
  43. Remove the EGR valve.
  44.  
  45. Remove the generator bracket.
  46.  
  47. Remove the upper intake manifold bolts and stud.
  48.  
  49. Remove the spark plug support bracket.
  50.  
  51. Remove the upper intake manifold.
  52.  
  53. Remove the upper intake manifold to lower intake manifold gaskets
  54.  
  55. Clean the upper and lower intake gasket mating surfaces.
  56.  
  57. If replacing the upper intake manifold, perform the following steps, remove the EVAP canister purge solenoid valve bolt.
  58.  
  59. Remove the EVAP canister purge solenoid valve and insulator.
  60.  
  61. Remove the throttle body bolts.
  62.  
  63. Remove the throttle body.
  64.  
  65. Remove and inspect the throttle body seal, replace as necessary.
  66.  
  67. Remove the MAP sensor bolt.
  68.  
  69. Remove the MAP sensor bracket and sensor.
  70.  
  71. Remove and inspect the throttle body seal, replace as necessary.
  72.  

To install:

  1. If installing a new intake manifold, perform the following steps:
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.



    Install the MAP sensor seal.
     
    Install the MAP sensor bracket and sensor.
     



    Install the MAP sensor bolt and tighten the bolt to 89 inch lbs. (10 Nm).
     
    Install the throttle body seal.
     
    Install the throttle body bolts and tighten the bolts to 89 inch lbs. (10 Nm).
     
    Position the EVAP canister purge solenoid valve insulator and valve to the intake.
     
    Install the EVAP canister purge solenoid valve bolt and tighten the bolt to 106 inch lbs. (12 Nm).
     

  2.  
  3. Install NEW upper and lower intake manifold gaskets.
  4.  
  5. Install the upper intake manifold.
  6.  
  7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the upper intake manifold bolt threads.
  8.  
  9. Install the spark plug support bracket onto one bolt, install the bolt.
  10.  
  11. Install the other upper intake manifold bolts and stud and tighten the bolts/stud to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the alternator bracket.
  14.  
  15. Install the EGR valve.
  16.  
  17. Install the ignition coil.
  18.  
  19. Install the thermostat bypass pipe.
  20.  
  21. Install the PCV foul air tube.
  22.  
  23. Position the PCV foul air tube clip.
  24.  
  25. Install the PCV foul air tube bolt and tighten the bolt to 89 inch lbs. (10 Nm).
  26.  
  27. Connect the spark plug wires to the ignition coil.
  28.  
  29. Install spark plug wire harness clips to the following:

    Ignition coil bracket
     
    Spark plug wire support
     
    Coolant bypass pipe
     

  30.  
  31. Connect the spark plug wires to the spark plugs.
  32.  
  33. Install the engine harness clips to the intake manifold.
  34.  
  35. Connect the EVAP canister purge valve electrical connector.
  36.  
  37. Connect the EGR valve electrical connector.
  38.  
  39. Install the engine harness clip to PCV foul air clip.
  40.  
  41. Connect the MAP sensor electrical connector.
  42.  
  43. Connect the electronic control module electrical connector.
  44.  
  45. Install the brake booster vacuum hose to the intake manifold.
  46.  
  47. Position the brake booster vacuum hose clamp at the intake manifold.
  48.  
  49. Install the PCV fresh air tube to the rocker cover.
  50.  
  51. Connect the EVAP canister purge solenoid valve quick connect fitting.
  52.  
  53. Install the air cleaner outlet duct.
  54.  
  55. Install the intake manifold cover.
  56.  
  57. Fill the cooling system.
  58.  

3.6L Engine
Lower
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Turn the ignition OFF .
  4.  
  5. Remove the air inlet duct.
  6.  
  7. Relieve the fuel pressure.
  8.  
  9. Disconnect the fuel pressure and evaporative emission (EVAP) hoses from the engine.
  10.  
  11. Disconnect the barometric pressure (BARO) sensor electrical connector.
    NOTE
    Do NOT disconnect the engine control module (ECM) electrical connectors.

  12.  
  13. Remove the ECM bracket with the ECM and reposition aside.
  14.  
  15. Raise and support the vehicle.
  16.  
  17. Disconnect the intermediate steering shaft from the steering gear.
  18.  
  19. Remove and reposition the front portion of the front fender liners in order to gain access to the frame front bolts.
  20.  
  21. Lower the vehicle.
  22.  
  23. Position a floor jack at the front center section of the frame in order to support the powertrain.
  24.  
  25. Remove the frame front bolts.
  26.  
  27. Carefully lower the powertrain or raise the vehicle enough to provide access.
  28.  
  29. Disconnect the purge solenoid electrical connector.
  30.  
  31. Remove the wiring harness from the right side of the intake manifold.
  32.  
  33. Disconnect the fuel injector electrical connector.
  34.  
  35. Disconnect the intake manifold runner control solenoid electrical connector.
  36.  
  37. Remove the throttle body electrical connector.
  38.  
  39. Remove the brake booster vacuum hose from the intake manifold.
  40.  
  41. Remove the positive crankcase ventilation (PCV) hose from the intake manifold and the cylinder head.
  42.  
  43. Remove the intake manifold bolts (1-6).
  44.  
  45. Remove the intake manifold.
  46.  
  47. Disassemble the intake manifold as necessary.
  48.  
  49. Clean and inspect the intake manifold and the sealing surfaces.
  50.  

To install

Click image to see an enlarged view

Fig. Lower intake manifold bolt torque sequence-3.6L engine

  1. Assemble the intake manifold as necessary.
  2.  
  3. Install the intake manifold. Tighten the bolts in the order shown to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the PCV hose to the intake manifold and the cylinder head.
  6.  
  7. Install the brake booster vacuum hose to the intake manifold.
  8.  
  9. Connect the throttle body electrical connector.
  10.  
  11. Connect the intake manifold runner control solenoid electrical connector.
  12.  
  13. Connect the fuel injector electrical connector.
  14.  
  15. Install the wiring harness to the right side of the intake manifold. Tighten the bracket bolts to 89 inch lbs. (10 Nm).
  16.  
  17. Connect the purge solenoid electrical connector.
  18.  
  19. Carefully raise the powertrain or lower the vehicle in order to install the frame bolts.
  20.  
  21. Install the frame front bolts. Torque to 114 ft. lbs. (155 Nm).
  22.  
  23. Remove the floor jack.
  24.  
  25. Raise and support the vehicle.
  26.  
  27. Install the front fender liners.
  28.  
  29. Connect the intermediate steering shaft to the steering gear.
  30.  
  31. Lower the vehicle.
  32.  
  33. Install the ECM bracket with the ECM.
  34.  
  35. Connect the BARO sensor electrical connector.
  36.  
  37. Connect the fuel pressure and EVAP hoses to the engine.
  38.  
  39. Install the air inlet duct.
  40.  

Upper
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Turn the ignition OFF .
  4.  
  5. Remove the air inlet duct.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Disconnect the fuel pressure and evaporative emission (EVAP) hoses from the engine.
  10.  
  11. Disconnect the BARO sensor electrical connector.
  12.  
  13. Remove the purge line from the purge line retainer.
  14.  
  15. Remove the fuel feed hose bracket bolt and reposition the fuel feed hose.
    NOTE
    Do NOT disconnect the engine control module (ECM) electrical connectors. Do NOT remove the ECM from the ECM bracket.

  16.  
  17. Remove the ECM bracket with the ECM and reposition aside.
  18.  
  19. Raise and support the vehicle.
  20.  
  21. Disconnect the intermediate steering shaft from the steering gear.
  22.  
  23. Remove and reposition the front portion of the front fender liners in order to gain access to the frame front bolts.
  24.  
  25. Lower the vehicle.
  26.  
  27. Position a floor jack at the front center section of the frame in order to support the powertrain.
  28.  
  29. Remove the frame front bolts.
  30.  
  31. Carefully lower the powertrain or raise the vehicle enough to provide access.
  32.  
  33. Disconnect the purge solenoid electrical connector.
  34.  
  35. Remove the wiring harness from the right side of the intake manifold.
  36.  
  37. Disconnect the fuel injector electrical connector.
  38.  
  39. Remove the fuel injector electrical connector from the fuel injector electrical connector bracket.
  40.  
  41. Disconnect the intake manifold runner control solenoid electrical connector.
  42.  
  43. Disconnect the throttle body electrical connector.
  44.  
  45. Remove the brake booster vacuum hose and check valve from the intake manifold.
  46.  
  47. Remove the positive crankcase ventilation (PCV) hose from the cylinder head and the intake manifold.
  48.  
  49. Remove the intake manifold bolts (1-6).
  50.  
  51. Remove the upper intake manifold.
  52.  
  53. Remove and discard the upper intake manifold gasket.
  54.  
  55. Disassemble the intake manifold if necessary.
  56.  
  57. Clean and inspect the intake manifold and the sealing surfaces.
  58.  

To install:

Click image to see an enlarged view

Fig. Upper intake manifold bolt loosening/tightening sequence-3.6L engine

  1. Assemble the intake manifold if necessary.
  2.  
  3. Install the intake manifold.
  4.  
  5. Install the intake manifold bolts (1-6). Tighten the bolts in the order shown to 17 ft. lbs. (23 Nm).
  6.  
  7. Install the PCV hose to the intake manifold and the cylinder head.
  8.  
  9. Install the brake booster vacuum hose and check valve to the brake booster.
  10.  
  11. Install the throttle body electrical connector.
  12.  
  13. Connect the intake manifold runner control solenoid electrical connector.
  14.  
  15. Install the fuel injector electrical connector to the fuel injector electrical connector bracket.
  16.  
  17. Install the fuel injector bracket.
  18.  
  19. Connect the fuel injector electrical connector.
  20.  
  21. Install the wiring harness and bracket to the right side of the intake manifold. Tighten the bracket bolts to 89 inch lbs. (10 Nm).
  22.  
  23. Connect the purge solenoid electrical connector.
  24.  
  25. Carefully raise the powertrain or lower the vehicle in order to install the frame bolts.
  26.  
  27. Install the frame front bolts. Torque to 114 ft. lbs. (155 Nm).
  28.  
  29. Remove the floor jack.
  30.  
  31. Raise and support the vehicle.
  32.  
  33. Install the front fender liners.
  34.  
  35. Connect the intermediate steering shaft to the steering gear.
  36.  
  37. Lower the vehicle.
  38.  
  39. Install the ECM bracket with the ECM.
  40.  
  41. Install the fuel feed hose bracket and the bracket bolt. Tighten the bracket bolt to 89 inch lbs. (10 Nm).
  42.  
  43. Connect the BARO sensor electrical connector.
  44.  
  45. Install the purge line to the purge line retainer.
  46.  
  47. Connect the fuel pressure and EVAP hoses to the engine.
  48.  
  49. Install the air inlet duct.
  50.  

 
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