Intake Manifold Replacement Upper Manifold

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -5.0, 5.7L.
4. Disconnect the following electrical connectors:

•	Fuel injector electrical connector. Refer to Fuel Meter Body Assembly Replacement in Engine Controls.

•	Manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.

•	EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.

•	Idle air control (IAC) solenoid. Refer to Idle Air Control Valve Replacement in Engine Controls.

•	Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.

5. Remove the vacuum brake booster hose, if equipped.
6. Remove the PCV tube at the intake manifold.

Twist to unlock the PCV tube.




7. Disconnect the spark plug wires from the left side of the distributor cap. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
8. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls -5.0, 5.7L.
9. Remove AIR Bypass hose assembly, if so equiped.
10. Remove the EVAP canister purge solenoid valve from the engine. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls -5.0, 5.7L.
11. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement in engine controls.
12. Remove the accelerator control cable bracket from the throttle body and the intake manifold and set it aside.



13. Remove the upper intake manifold bolts from the engine and then remove the upper intake manifold.
14. Clean all sealing surfaces.

Notice: 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.

1. Install the upper intake manifold to the engine.

Tighten

1. Tighten the upper intake manifold studs on the first pass to 12 N·m44 lb in.
2. Tighten the upper intake manifold studs on the second pass to 10 N·m 89 lb in.

Notice: 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.

2. Install the accelerator control cable bracket (3) to the throttle body and the lower intake manifold.

Tighten
Tighten the bolts and nut to 12 N·m (106 lb in).

3. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft . Refer to Accelerator Control Cable Replacement in Engine Controls.
4. Install the EVAP canister purge solenoid valve to the engine. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls -5.0, 5.7L.
5. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls -5.0, 5.7L.



6. Connect the spark plug wires to the left side of the distributor cap.

The wires and the distributor cap are numbered in order to aid assembly.

7. Install AIR bypass hose assembly, if so equiped.
8. Install the PCV tube to the intake manifold. Twist to lock the PCV tube .
9. Install the vacuum brake booster hose to the intake manifold, if equipped.
10. Connect the following electrical connectors:

•	Fuel injector electrical connector. Refer to Fuel Meter Body Assembly Replacement in Engine Controls.

•	Manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.

•	EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.

•	Idle air control (IAC) solenoid. Refer to Idle Air Control Valve Replacement in Engine Controls.

•	Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.

11. Install the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Intake Manifold Replacement Lower Manifold

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Assembly Replacement in Engine Controls.
4. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
5. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement
6. Remove the following coolant hoses:

6.1.	Upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.

6.2.	Inlet heater hose. Refer to Heater Hoses Replacement in HVAC- non AC equipped.

6.3.	Outlet heater hose. Refer to Heater Hoses Replacement in HVAC-non AC equipped.

6.4.	Coolant by-pass hose. Refer to Coolant Bypass Hose Replacement in Engine Cooling.

7. Disconnect the following electrical connectors.

•	SCPI injector electrical connector. Refer to Fuel Meter Body Assembly Replacement in Engine Controls.

•	Manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.

•	EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.

•	Idle air control (IAC) motor. Refer to Idle Air Control Valve Replacement in Engine Controls.

•	Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.

•	Exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.

•	Engine coolant temperature (ECT) sensor. Refer to Engine Coolant Temperature Sensor Replacement in Engine Controls.

8. Remove AIR bypass hose assembly, if so equiped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls.
9. Use a twisting motion in order to remove the brake booster vacuum hose, if equipped. Refer to Power Vacuum Brake Booster Replacement in Brakes.
10. Remove the distributor from the engine. Refer to Distributor Replacement in Engine Electrical.
11. Remove the fuel pipes from the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-5.0/5.7L.



12. Remove the accelerator control cable and the cruise control cables, if equipped, from the throttle shaft. Refer to Accelerator Control Cable Replacement in Engine Controls.
13. Remove the accelerator control cable bracket from the throttle body and the lower intake manifold.
14. Remove the ignition coil and ICM bracket. Refer to Ignition Coil and Ignition Coil Module Replacement in Engine Electrical.
15. Remove the EGR pipe from the intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.




Important: It is not necessary to discharge the A/C refrigerant.

16. Remove the air conditioning (A/C) compressor, if equipped, and set aside. Refer to Air Conditioning Compressor Replacement in HVAC.
17. Remove the power steering pulley from the power steering pump. Refer to Power Steering Pump Pulley Replacement in Steering.
18. Remove the power steering pump mounting bracket . Refer to Accessory Mounting Brackets Replacement .
19. Remove the leftside valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
20. Remove the rightside valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .



21. Remove the lower intake manifold from the engine.
22. Clean all sealing surfaces.

1. Install the lower intake manifold to the engine. Refer to Intake Manifold Installation .
2. Install the leftside valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
3. Install the rightside valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
4. Install the power steering pump mounting bracket . Refer to Accessory Mounting Brackets Replacement .
5. Install the air conditioning (A/C) compressor, if equipped. Refer to Air Conditioning Compressor Replacement in HVAC.



6. Connect the exhaust gas recirculation (EGR) pipe to the bracket and the front of the intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.
7. Install the ignition coil and the ICM bracket. Refer to Ignition Coil and Ignition Coil Module Replacement in Engine Controls.
8. Install AIR bypass hose assembly, if so equiped.



9. Install the accelerator control cable bracket to the throttle body and the lower intake manifold. Refer to Accelerator Control Cable Replacement in Engine Controls.
10. Install the accelerator control cable and the cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Control Cable Replacement .
11. Install the fuel pipes to the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
12. Install the distributor to the engine. Refer to Distributor Replacement .
13. Install the PCV tube at intake manifold using a twisting motion in order to lock.
14. Install the vacuum brake booster hose, if equipped.
15. Connect the following electrical connectors:

•	SCPI injector electrical connector. Refer to Fuel Meter Body Assembly Replacement in Engine Controls.

•	Manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls.

•	EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.

•	Idle air control (IAC) motor. Refer to Idle Air Control Valve Replacement in Engine Controls.

•	Throttle position (TP) sensor. Refer to Throttle Position Sensor Replacement in Engine Controls.

•	Exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.

•	Engine coolant temperature (ECT) sensor. Refer to Engine Coolant Temperature Sensor Replacement in Engine Controls.

16. Install the AIR bypass hose assembly, if so equipped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement in Engine Controls.
17. Install the brake booster vacuum hose, if so equipped. Refer to Power Vacuum Brake Booster Replacement in Brakes.
18. Install the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
19. Install the inlet heater hose. Refer to Heater Hoses Replacement in HVAC.
20. Install the outlet heater hose. Refer to Heater Hoses Replacement in HVAC.
21. Install the coolant bypass hose. Refer to Coolant Bypass Hose Replacement in Engine Cooling.
22. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
23. Install the engine cover. Refer to Engine Cover Replacement Engine Cover in Interior Trim.
24. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
25. Fill the engine with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
26. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.