Intake Manifold

REMOVAL & INSTALLATION

2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the engine coolant.
3. Relieve the fuel pressure.
4. Remove or disconnect the following:
   • Negative battery cable

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

5. Upper radiator hose from the thermostat housing
6. Air intake hoses, breather hose and the air intake pipe
7. Wires, hoses and linkages from the throttle body
8. Ignition coil
9. Brake booster hose and vacuum hose cluster from the air intake plenum
10. Air intake plenum from the intake manifold
11. Fuel lines, keep the line covered or plugged
12. Fuel rail assembly with injectors intact
13. Heater hose from the manifold
14. Engine Coolant Temperature (ECT) sensor
15. Water outlet fitting
16. Distributor, matchmark for reassembly
17. Intake manifold from the cylinder head and engine
18. Manifold Differential Pressure (MDP) sensor, if equipped
19. Clean and dry the mating surfaces of the manifold and cylinder head.

    To install:

20. 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
21. Refill the radiator with coolant.
22. Check the system for leaks.

    Fig. 1: Exploded view of the intake plenum chamber and related components — 2.4L engine shown

    Fig. 2: Exploded view of the intake manifold and related components — 2.4L engine shown

3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. 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.

3. Drain the engine coolant.
4. Remove or disconnect the following:
   • Negative battery cable

   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.

5. Air intake hose from the throttle body
6. Positive Crankcase Ventilation (PCV) hose
7. Exhaust Gas Recirculation (EGR) valve
8. Manifold Differential Pressure (MDP) sensor
9. Vacuum hoses from the throttle body and air intake plenum
10. Accelerator cable and the throttle control cable
11. Coolant hoses
12. Engine oil filler neck bracket from the air intake plenum
13. EGR tube from the air intake plenum
14. Plenum brackets
15. Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed.
16. Fuel hose from the fuel rail
17. Fuel return line and vacuum hose from the fuel pressure regulator
18. Electrical connectors from the injectors
19. Fuel rail and injectors
20. Intake manifold
21. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.

    To install:

22. Install or connect the following:
    • Intake manifold. Torque the nuts to 16 ft. lbs. (21 Nm) start from the center and working outward.
23. Connect the hoses and connect the wires to the coolant switches.
24. Fuel rail assembly and connect the fuel hoses
25. New gasket and the air intake plenum to the intake manifold. Torque the nuts/bolts to 13 ft. lbs. (17 Nm).
26. Plenum brackets
27. PCV hose and vacuum hose cluster to the plenum
28. EGR tube
29. EGR temperature sensor wire
30. Wires, hoses and linkages to the throttle body
31. Air intake hose to the throttle body
32. Upper radiator hose to the thermostat housing
33. Negative battery cable
34. Refill the radiator with coolant.
35. Check fuel system for leaks.

    Fig. 3: Exploded view of the upper intake manifold and related components — 3.0L 24-valve engine shown

    Fig. 4: Exploded view of the lower intake manifold and related components — 3.0L 24-valve engine shown

3.5L Engines

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. Relieve the fuel pressure.
3. Partially drain the cooling system.
4. Remove or disconnect the following:
   • Negative battery cable

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

5. Air intake hose from the throttle body
6. Electrical connectors and vacuum hoses from the throttle body and air intake plenum
7. Accelerator cable and the throttle control cable
8. Coolant hoses
9. Positive Crankcase Ventilation (PCV) hose
10. Exhaust Gas Recirculation (EGR) temperature sensor connector
11. EGR tube from the air intake plenum
12. Intake manifold plenum cover
13. Intake manifold plenum stay brackets
14. Air intake plenum assembly from the intake manifold and remove. Note the position of the mounting bolts as they are removed
15. Induction control valve assembly
16. Fuel hose from the fuel rail
17. Fuel return line and vacuum hose from the fuel pressure regulator
18. Electrical connectors from the injectors
19. Fuel rail and injectors
20. Intake manifold
21. Remove the gaskets and thoroughly clean and dry the mating surfaces of the manifold and heads.

    To install:

22. 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
23. Refill the radiator with coolant.
24. Check the system for fuel leaks.
25. Set all adjustments to specifications.