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Expert
65 Answers
- Posted on Sep 16, 2009
Re: intake manifold gasket / replace
3.8L Engine
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.
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Disconnect the negative battery cable.
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On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
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Remove the upper intake manifold using the procedure above.
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Remove the EGR outlet pipe from the intake manifold.
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Detach the engine coolant temperature sensor wiring harness from the sensor.
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Remove the lower intake manifold bolts and carefully lift off the manifold.
To install:
Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine
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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..
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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.
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Install the remaining components in the reverse order of the removal process.
Upper Intake Manifold (Plenum)
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Disconnect the negative battery cable.
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On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
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Tag for identification, then remove the right side spark plug wires.
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Disconnect the ignition wires from the fuel rail.
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Remove the fuel rail. Please see Section 5.
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Remove the cable bracket from the intake manifold.
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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.
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Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engintake manifold gasket / replace - 0900c15280269f1c.jpg/ol>
Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine
To install:
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Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
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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.
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Install the remaining components in the reverse order of the removal process.
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