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Posted on Mar 25, 2011

How do I remove the intake manifold above the engine where plugs are located on a 2001 galant.

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  • Posted on Mar 25, 2011
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Need to remove upper intake manifold to reach valve cover close to firewall.
1) The location of spark plugs 456 are under the plastic shield in front of the engine. It takes an 8mm socket to remove the three bolts holding the shield once the shield is removed you will see a coil for each spark plug. Use the 8mm socket and remove the coil and rubber boots. You will now see the spark plug (note there are not any spark plug wires).
2) The location of spark plugs 123 are located to the rear of the eng. You have to remove the air intake manifold in order to get to the spark plus. Remove the throttle wire then remove the other items on top of the intake manifold.
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I keep getting a notice that the #2 and #4 cyclinder is misfiring. I went to change the plugs, but could not locate them from the top of the engine. Where are the plugs located at?

Need to remove upper intake manifold to reach valve cover close to firewall. 1) The location of spark plugs 456 are under the plastic shield in front of the engine. It takes an 8mm socket to remove the three bolts holding the shield once the shield is removed you will see a coil for each spark plug. Use the 8mm socket and remove the coil and rubber boots. You will now see the spark plug (note there are not any spark plug wires). 2) The location of spark plugs 123 are located to the rear of the eng. You have to remove the air intake manifold in order to get to the spark plus. Remove the throttle wire then remove the other items on top of the intake manifold. 3) Loosen all the bolts holding the manfold. 8mm socket-- I think three in front and three in the middle. Remove the EGR valve mounts so you can slide the manifold out. Disconnet all vacuum lines from manifold and the air filter inlet closet to manifold. Just take a general look and ensure you have all wiring and tubing disconnected then slide the manifold off the eng and EGR valve. NOW MAKE SURE you cover all intake holes (leading into the engine) with paper towels to prevent droping screws etc into the engine. Then follow step 1 above
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Intake manifold gasket / replace

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NOTE The 3.8L (VIN K) non-supercharged engine uses a two-piece intake manifold consisting of an upper air plenum which mounts the throttle body and a lower intake manifold assembly which houses the fuel injectors. The 3.8L (VIN 1) supercharged engine uses a similar lower intake manifold. The supercharger serves as the upper manifold.
Lower Manifold

NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
The 3.8L (VIN 1) supercharged engine uses a manifold similar to the 3.8L (VIN K), but the supercharger serves as the upper manifold.
  1. Disconnect the negative battery cable.
  2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
  3. Remove the upper intake manifold using the procedure above.
  4. Remove the EGR outlet pipe from the intake manifold.
  5. Detach the engine coolant temperature sensor wiring harness from the sensor.
  6. Remove the lower intake manifold bolts and carefully lift off the manifold.

To install:


0900c15280269f1b.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine
  1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces and between the lower manifold and the cylinder heads..
  2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Apply thread-locking compound to the bolt threads. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 11 ft. lbs. (15 Nm). Follow the toque sequence, starting in the center, then working outwards in a circle.
  3. Install the remaining components in the reverse order of the removal process.

Upper Intake Manifold (Plenum)
  1. Disconnect the negative battery cable.
  2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
  3. Tag for identification, then remove the right side spark plug wires.
  4. Disconnect the ignition wires from the fuel rail.
  5. Remove the fuel rail. Please see Section 5.
  6. Remove the cable bracket from the intake manifold.
  7. Remove the throttle body.


NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold.
  1. Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engine.



0900c15280269f1c.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine
To install:
  1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
  2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 89 inch lbs. (10 Nm). Follow the torque sequence, starting in the center, then working outwards in a circle.
  3. Install the remaining components in the reverse order of the removal process.
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2002 Mitsubishi Galant gets poor acceleration.

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