There is a vacuum line off the intake plenum that goes to a check valve and a return fuel line off the fuel regulator to another check valve. Both connect through a "T" and go to the EVAP can by the f

Removal & Installation

Disconnect the Negative battery cable

Relieve the fuel system pressure (you can do this by placing a rag over the schrader valve on the fuel rail and pressing in the valve stem--just be careful not to spray fuel on your eyes).

Drain the cooling system.

Remove or disconnect the following:

• Intake manifold heat shield

• Sight shield
• Coil module connectors from the coil modules located on the valve covers

• Positive Crankcase Ventilation (PCV) hose and valve from the valve cover
• Fuel regulator vacuum tube
• Vacuum tubes from the AIR solenoid
• Fuel inlet and return lines
• Fuel rail bracket retaining nut at the rear lift bracket
• 2 pushnuts attaching the engine coolant heater wire and set it aside, if equipped
• Fuel injector electrical connections
• Fuel rail and injectors
• Plenum duct clamp at the rear of the intake manifold, loosen
• Intake manifold bolts and the manifold

Remove or disconnect the following:
Starter electrical connectors Starter motor

Fig. View of starter motor removal and wires

To install:

Install or connect the following:

• -S- terminal wire. Torque the nut to 35 inch lbs. (4 Nm).
• Starter electrical connectors. Torque the nut to 89 inch lbs. (10 Nm).
• Starter motor
• Mounting bolts. Torque the bolts to 22 ft. lbs. (30 Nm).

Fig. Intake manifold torque sequence- 4.6L engines

1. Grease the inside edge of the rubber plenum duct.
2. Position the intake manifold by performing the following sub-steps:
   1. Place the rear of the intake manifold into the plenum duct.
   2. Place the front of the intake manifold downward on to the cylinder heads.
   
   
3. Install the intake manifold bolts and torque to 89 inch lbs. (10 Nm) in the sequence illustrated. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature.
4. Make sure the plenum duct is fully attached to the rear of the intake manifold and tighten the plenum duct clamp to 20 inch lbs. (2.25 Nm).
5. Install or connect the following:
   
   Fuel rail and injectors and tighten the rail retainers to 89 inch lbs. (10 Nm) Fuel injector electrical connections Alternator coolant pipe/surge tank pipe and position onto the fuel rail studs Engine coolant heater wire onto the studs and install the pushnuts, if equipped Fuel rail bracket retaining nut at the rear lift bracket and tighten to 89 inch lbs. (10 Nm) Fuel inlet and return lines Vacuum tubes to the AIR solenoid Fuel regulator vacuum tube Positive Crankcase Ventilation (PCV) valve and hose to the valve cover Coil module connectors to the coil modules located on the valve covers Sight shield Intake manifold heat shield Negative battery cable
   
6. Fill and bleed the cooling system.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Remove top half of the air cleaner assembly and throttle body duct.
4. Drain and recycle the engine coolant.
5. Disconnect the EGR pipe from exhaust manifold.
6. Remove the serpentine belt.
7. Remove the brake vacuum pipe at the intake plenum.
8. Disconnect the control cables from the throttle body and intake plenum mounting bracket.
9. Remove the power steering lines at the alternator bracket.
10. Remove the alternator.
11. Label and disconnect the ignition wires from the spark plugs and wire retainers on the intake plenum.
    
12. Remove the ignition assembly and the EVAP canister purge solenoid together.

Fig. 14: View of the intake manifold and related components

1. Disconnect the upper engine wiring harness connectors at the following components:
   Throttle Position Sensor (TPS) Idle Air Control (IAC) Fuel Injectors Coolant temperature sensor Manifold Absolute Pressure (MAP) sensor Camshaft Position (CMP) sensor
2. Tag and disconnect the vacuum lines from the following components:
   Vacuum modulator Fuel pressure regulator PCV valve
3. Disconnect the MAP sensor from upper intake manifold.
4. Remove the upper intake plenum mounting bolts and lift off the plenum.
5. Disconnect the fuel lines from the fuel rail and bracket.
6. Install engine support fixture special tool J 28467-A or an equivalent.
7. Remove the right side engine mount.
8. Remove the power steering mounting bolts and support the pump out of the way without disconnecting the power steering lines.
9. Disconnect the coolant inlet pipe from the outlet housing.
10. Remove the coolant bypass hose from the water pump and the cylinder head.
11. Disconnect the upper radiator hose at thermostat housing.
12. Remove the thermostat housing.
13. Remove both rocker arm covers.
14. Remove the lower intake manifold bolts. Make sure the washers on the four center bolts are installed in their original locations.
    

1. Remove the rocker arm retaining nuts or bolts and extract the rocker arms and pushrods.
2. Remove the intake manifold from the engine. Remove and discard the gasket.
3. Using a suitable scraper, clean gasket material from all mating surfaces. Remove all excess RTV sealant from front and rear ridges of cylinder block
   

1. Place a 0.12 inch (3mm) bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block.
2. Using a new gasket, place the intake manifold on the engine.
3. Install the pushrods in their original locations. Coat the pushrods with prelube.

1. Position the rocker arms in there original locations and tighten to specifications. Refer to the procedure earlier in this section.
2. Install lower the intake manifold attaching bolts. Apply sealant 12345739 (or equivalent thread locking compound) to the threads of bolts. Tighten the vertical bolts first then the diagonal bolts to 115 inch lbs. (13 Nm).
3. Install the front rocker arm cover.
4. Install the thermostat housing.
5. Connect the upper radiator hose to the thermostat housing.
6. Fasten the coolant inlet pipe to thermostat housing.
7. Connect coolant bypass pipe at the water pump and cylinder head.
8. Install the power steering pump in the mounting bracket.
9. Loosely install the serpentine belt.
10. Connect the right side engine mount.
11. Remove the special engine support tool.
12. Fasten the fuel lines to fuel rail and bracket.
13. Install the upper intake manifold and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
14. Install the MAP sensor.
15. Connect the upper engine wiring harness connectors to the related components removed earlier.
16. Connect the vacuum lines to the PCV, vacuum modulator and fuel pressure regulator.
17. Install the EVAP canister purge solenoid and ignition assembly.
18. Install the alternator assembly.
19. Connect the power steering line to the alternator bracket.
20. Install the serpentine belt.
21. Connect the spark plug wires to the spark plugs and intake plenum wire retainer.
22. Install the EGR pipe to the exhaust manifold.
23. Attach the control cables to the throttle body lever and upper intake plenum mounting bracket.
24. Install air intake assembly and top half of the air cleaner assembly.
25. Install the brake vacuum pipe.
26. Fill the cooling system.
27. Connect the negative battery cable, then start the vehicle and verify that there are no leaks.

1. Negative battery cable
2. Intake manifold
3. Starter electrical connectors
4. Starter motor

1. -S- terminal wire. Torque the nut to 35 inch lbs. (4 Nm).
2. Starter electrical connectors. Torque the nut to 89 inch lbs. (10 Nm).
3. Starter motor
4. Mounting bolts. Torque the bolts to 22 ft. lbs. (30 Nm).
5. Intake manifold
6. Negative battery cable

• Relieve the fuel system pressure
• Drain the cooling system.

1. Negative battery cable
2. Intake manifold heat shield
3. Sight shield
4. Coil module connectors from the coil modules located on the valve covers
5. Positive Crankcase Ventilation (PCV) hose and valve from the valve cover
6. Fuel regulator vacuum tube
7. Vacuum tubes from the AIR solenoid
8. Fuel inlet and return lines
9. Fuel rail bracket retaining nut at the rear lift bracket
10. 2 pushnuts attaching the engine coolant heater wire and set it aside, if equipped
11. Fuel injector electrical connections
12. Fuel rail and injectors
13. Plenum duct clamp at the rear of the intake manifold, loosen Intake manifold bolts and the manifold
14. Clean the manifold mating surfaces.

• Grease the inside edge of the rubber plenum duct.
• Position the intake manifold by performing the following sub-steps:
• Place the rear of the intake manifold into the plenum duct.
• Place the front of the intake manifold downward on to the cylinder heads.
• Install the intake manifold bolts and torque to 89 inch lbs. (10 Nm) in the sequence illustrated. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature.
• Make sure the plenum duct is fully attached to the rear of the intake manifold and tighten the plenum duct clamp to 20 inch lbs. (2.25 Nm).

1. Fuel rail and injectors and tighten the rail retainers to 89 inch lbs. (10 Nm)
2. Fuel injector electrical connections
3. Alternator coolant pipe/surge tank pipe and position onto the fuel rail studs
4. Engine coolant heater wire onto the studs and install the pushnuts, if equipped
5. Fuel rail bracket retaining nut at the rear lift bracket and tighten to 89 inch lbs. (10 Nm)
6. Fuel inlet and return lines
7. Vacuum tubes to the AIR solenoid
8. Fuel regulator vacuum tube
9. Positive Crankcase Ventilation (PCV) valve and hose to the valve cover
10. Coil module connectors to the coil modules located on the valve covers
11. Sight shield
12. Intake manifold heat shield
13. Negative battery cable
14. Fill and bleed the cooling system.

1. Before servicing the vehicle, refer to the Precautions section.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   Negative battery cable Supercharger Thermostat housing Exhaust Gas Recirculation (EGR) tube at the intake manifold Engine Control Temperature (ECT) sensor Intake manifold

1. Install or connect the following:
   Intake manifold with new gaskets. Torque the bolts, working from the center out, to 11 ft. lbs. (15 Nm). ECT sensor connector EGR tube to the intake manifold Thermostat housing Supercharger Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Relieve the fuel system pressure.
5. Remove or disconnect the following:
   Fuel injector sight shield Air inlet duct Spark plug wires from the right side Manifold Absolute Pressure (MAP) sensor Vacuum lines from the intake manifold Fuel lines Fuel injector electrical connectors Fuel regulator vacuum line Fuel rail from the intake manifold Exhaust Gas Recirculation (EGR) heat shield Throttle cable bracket from the cylinder head mounting bracket and the throttle body cables Throttle body support bracket Upper intake plenum and gasket Thermostat housing Electrical connector from the Engine Coolant Temperature (ECT) sensor Drive belt tensioner assembly EGR valve outlet pipe Lower intake manifold
   
   
   Fig. Exploded view of the intake manifold and related components-3.8L (VIN K) engine
   

1. Install or connect the following:
   Intake manifold using new manifold gaskets. Torque the bolts in sequence to 11 ft. lbs. (15 Nm); then, re-torque to 11 ft. lbs. (15 Nm). EGR valve outlet pipe Drive belt tensioner assembly. Torque the tensioner bolts to 37 ft. lbs. (50 Nm). Electrical connector to the ECT sensor Thermostat housing Upper intake plenum. Torque the intake plenum bolts to 88 inch. lbs. (10 Nm). Throttle body support bracket Throttle cable bracket to the cylinder head mounting bracket and the cables to the throttle body lever EGR heat shield Fuel rail. Torque the fuel rail bolts to 88 inch. lbs. (10 Nm). Fuel lines Fuel regulator vacuum line Fuel injector electrical connectors Vacuum lines to the intake manifold MAP sensor Spark plug wires Fuel injector sight shield and air inlet duct Negative battery cable
2. Refill and bleed the cooling system.
3. Run the engine and check for leaks and proper engine operation.