Upper Intake Manifold Replacement

Upper Intake Manifold Replacement

Removal Procedure




1. Disconnect the negative battery cable.
2. Remove the intake manifold cover.
3. Drain the cooling system. Refer to Draining and Filling Cooling System (9C1, 9C3 Static Fill) Draining and Filling Cooling System (LS4 GE 47716 Fill) Draining and Filling Cooling System (LS4 Static Fill) Draining and Filling Cooling System (LZE, LZ4, LZ8, 9C1, 9C3, GE47716 Fill) Draining and Filling Cooling System (LZE, LZ4, LZ8 Static Fill).
4. Remove the positive crankcase ventilation (PCV) fresh air tube.




5. Remove the PCV foul air tube.




6. Remove the brake booster vacuum hose from the intake manifold fitting.




7. Reposition the heater inlet and outlet hose/pipe clamps at the engine pipes.
8. Remove the heater inlet and outlet hose/pipe clamp nuts from the throttle body studs.
9. Remove the heater inlet and outlet hoses/pipes from the engine pipes and the throttle body studs.
10. Reposition the hoses/pipes out of the way.




11. Remove the fuel feed and evaporative emission (EVAP) line clip from the manifold absolute pressure (MAP) sensor bracket.
12. Disconnect the MAP sensor electrical connector (1).




13. Disconnect the EVAP canister purge solenoid electrical connector (1).
14. Disconnect the chassis EVAP line quick connect fitting from the purge solenoid.
15. Disconnect the electronic throttle control (ETC) electrical connector (2).




16. Disconnect the intake manifold tuning valve electrical connector.




17. Remove the air cleaner outlet duct.
18. Disconnect the left side spark plug wires from the spark plugs.
19. Disconnect the left side spark plug wires from the ignition coil.
20. Disengage the spark plug wire retainer clips from the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
21. Remove the left side spark plug wires.




22. Remove the throttle body bolts and nuts.
23. Remove the throttle body and gasket.




24. Remove the EVAP canister purge solenoid valve bolt.
25. Remove the EVAP canister purge solenoid valve.




26. Remove the MAP sensor bracket/upper intake manifold bolts.
27. Remove the MAP sensor bracket and sensor.




28. Remove the ignition coil bracket to intake manifold bolts.
29. Remove the intake manifold cover ball stud nut from the intake manifold stud.
30. Remove the upper intake manifold bolts and stud.
31. Separate and remove the upper intake manifold from the lower intake manifold.
32. Remove the upper to lower intake manifold gaskets.




33. Remove the intake manifold tuning valve bolts, valve, and seal.
34. Clean the upper intake to lower intake gasket mating surfaces.

Installation Procedure




1. Inspect the intake manifold tuning valve seal for damage. The tuning valve blade attachment to motor should be tight, with no looseness or slack present. Replace as necessary.
2. Apply lubricant to the nose of the valve blade (1). Refer to Sealers, Adhesives, and Lubricants for the 3.9L engine.





Notice: Refer to Fastener Notice.

3. Install the intake manifold tuning valve seal, valve, and bolts.

Tighten the bolts to 10 N.m (89 lb in).




4. Install NEW upper to lower intake manifold gaskets.
5. Install the upper intake manifold onto the lower intake manifold.
6. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to Sealers, Adhesives, and Lubricants for the 3.9L engine.
7. Install the upper intake manifold bolts and stud.

Tighten the bolts and stud to 25 N.m (18 lb ft).

8. Install the intake manifold cover ball stud nut to the intake manifold stud.

Tighten the nut to 5 N.m (44 lb in).

9. Install the ignition coil bracket to intake manifold bolts.

Tighten the bolts to 25 N.m (18 lb ft).




10. Install the MAP sensor and bracket.
11. Install the MAP sensor bracket/upper intake manifold bolts.

Tighten the bolts to 25 N.m (18 lb ft).




12. Install the EVAP canister purge solenoid valve.
13. Install the EVAP canister purge solenoid valve bolt.

Tighten the bolts to 16 N.m (12 lb ft).




14. Inspect the throttle body seal for damage. Replace as necessary.
15. Apply threadlock to the throttle body bolts/studs threads. Refer to Sealers, Adhesives, and Lubricants for the 3.9L engine.
16. Position the throttle body gasket and throttle body to the intake.
17. Install the throttle body bolts and nuts.

Tighten the bolts/studs to 10 N.m (89 lb in).




18. Install the left side spark plug wires.
19. Engage the spark plug wire retainer clips to the intake manifold bracket and the heater inlet/outlet hose/pipe bracket.
20. Connect the left side spark plug wires to the ignition coil.
21. Connect the left side spark plug wires to the spark plugs.
22. Install the air cleaner outlet duct.




23. Connect the EVAP canister purge solenoid electrical connector (1).
24. Connect the chassis EVAP line quick connect fitting to the purge solenoid.




26. Connect the MAP sensor electrical connector (1).
27. Install the fuel feed and EVAP line clip to the MAP sensor bracket.




28. Position the hoses/pipes.
29. Install the heater inlet and outlet hoses/pipes to the engine pipes and the throttle body studs.
30. Install the heater inlet and outlet hose/pipe clamp nuts to the throttle body studs.

Tighten the nuts to 10 N.m (89 lb in).

31. Position the heater inlet and outlet hose/pipe clamps at the engine pipes.




32. Install the brake booster vacuum hose to the intake manifold.




33. Install the PCV foul air tube.




34. Install the PCV fresh air tube.
35. Fill the cooling system. Refer to Draining and Filling Cooling System (9C1, 9C3 Static Fill) Draining and Filling Cooling System (LS4 GE 47716 Fill) Draining and Filling Cooling System (LS4 Static Fill) Draining and Filling Cooling System (LZE, LZ4, LZ8, 9C1, 9C3, GE47716 Fill) Draining and Filling Cooling System (LZE, LZ4, LZ8 Static Fill).
36. Install the intake manifold cover.
37. Connect the negative battery cable.