Upper Intake Manifold Replacement

Upper Intake Manifold Replacement (SFI) (3.6 L)

Removal Procedure




1. Turn the ignition OFF.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (SFI) (Service and Repair)Fuel Injector Sight Shield Replacement (DI) (Service and Repair).
3. Remove the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement (DI) (Air Cleaner Outlet Duct Replacement (DI))Air Cleaner Outlet Duct Replacement (SFI) (Air Cleaner Outlet Duct Replacement (SFI)).
4. Disconnect the brake booster vacuum hose (1) from the intake manifold (2) and the power steering booster pump (3).




5. Remove the purge solenoid valve bracket.
6. Disconnect the purge line (1) from the intake manifold (2).




7. Remove the throttle body harness electrical harness retainer (1).
8. Disconnect the throttle body electrical connector (2).




9. Remove the intake manifold brace bolts (1).
10. Remove the intake manifold brace.




11. Disconnect the positive crankcase ventilation (PCV) hose (1) from the intake manifold (3).




12. Unclip the engine harness from the left side of the intake manifold.
13. Remove the intake manifold rear heat shield bolts (1).




14. Remove the intake manifold bolts (1). Some deflection of the cowl panel may be necessary to extract the right rear bolt.
15. Remove the intake manifold with the throttle body.
16. If the intake manifold is being replaced, disassemble the intake manifold. Refer to Intake Manifold Disassemble. Overhaul
17. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection. Overhaul

Installation Procedure




1. If the intake manifold is being replaced, assemble the intake manifold. Refer to Intake Manifold Assemble. Overhaul
2. Install a NEW intake manifold gasket.
3. Install the intake manifold.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: Tighten the intake manifold bolts in a circular pattern starting at the center (long bolts) and moving outward.

4. Install the intake manifold bolts (1) and tighten to 23 Nm (17 lb ft).




5. Install the intake manifold rear heat shield bolts (1) and tighten to23 Nm (17 lb ft).
6. Clip the engine harness from the left side of the intake manifold.




7. Connect the positive crankcase ventilation (PCV) hose (1) to the intake manifold (3).




8. Position the intake manifold brace.
9. Install the intake manifold brace bolts (1) and tighten to23 Nm (17 lb ft).





Caution: Ensure proper engagement of the wiring harness connector. The wiring harness connector must be installed straight onto the component connector and firmly seated. Visually inspect the connector to ensure that the connector latches are engaged and locked. Any damage to the connector or wiring must be repaired. Failure to follow this procedure can lead to an intermittent electrical connection, driveability concerns, and/or wiring harness or wiring harness connector damage or failure.

10. Connect the electrical connector (2) to the throttle body.
11. Install the throttle body harness electrical harness retainer (1).




12. Connect the purge line (1) to the intake manifold (2).
13. Install the purge solenoid valve bracket and bolts to tighten to23 Nm (17 lb ft).




14. Connect the brake booster vacuum hose (1) to the power steering booster pump (3) and the intake manifold (2).
15. Install the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement (DI) (Air Cleaner Outlet Duct Replacement (DI))Air Cleaner Outlet Duct Replacement (SFI) (Air Cleaner Outlet Duct Replacement (SFI)).
Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (SFI) (Service and Repair)Fuel Injector Sight Shield Replacement (DI) (Service and Repair).