Intake Plenum

Removal & Installation

3.8L Engine

To Remove:

1. Partially drain the engine coolant.
2. Remove the engine cover.
3. Remove the air cleaner cover and duct.
4. Remove the throttle body.
5. Disconnect the MAP sensor connector.
6. Disconnect the engine control and injector harness combination connector.
7. Disconnect the following;
   • CKP sensor
   • Knock sensor
   • Power steering pressure switch
   • EVAP purge solenoid
   • EGR valve
8. Disconnect the vacuum hose and purge hose.
9. Remove the clamp and bracket from the power steering pressure hose.
10. Remove the rear intake plenum stay.
11. Remove the EGR pipe.
12. Remove the power steering pump and bracket.
13. Remove the front intake plenum stay.
14. Remove the intake manifold plenum and gasket.

To Install:

1. Install the intake manifold plenum and gasket using the special tools as shown.
2. Install the front intake plenum stay.
3. Install the power steering pump and bracket.
4. Install the EGR pipe.
5. Install the rear intake plenum stay.
6. Install the clamp and bracket on the power steering pressure hose.
7. Connect the following;
   • CKP sensor
   • Knock sensor
   • Power steering pressure switch
   • EVAP purge solenoid
   • EGR valve
8. Connect the engine control and injector harness combination connector.
9. Connect the MAP sensor connector.
10. Install the throttle body.
11. Install the air cleaner cover and duct.
12. Install the engine cover.
13. Refill the cooling system.