The next process is used on 3.0L engines and on the upper intake manifold of 3.2L engines. Firstly, it is important to take the pressure off the fuel system and take the cable off the battery negative post. Semi-drain the engine coolant, and disconnect the electrical connector of throttle body. Take out the engine covers, air intake tube, air filter housing, and coolant expansion tank. Unscrew the crankcase breather tube of the
Valve Covers and rear of the intake manifold, labeling and disconnecting any hoses or electrical connectors at the intake manifold. Take out the oil dipstick and the bolt that holds the dipstick tube to the valve cover and turn the tube so that it will be out of the way. Take off the ignition coils and lay the harnesses aside, and then take off the bolts holding the AIR pipe to the heads or the valve covers. In the case of an engine that uses 3.0L, de-fit the fuel rail and injectors. Disassemble and take off mounting fasteners and the manifold of the engine. Wipe all traces of gasket material off the manifold and the
Cylinder Head and remove the O-ring gaskets off of the receiver grooves on the intake manifold when fitted. Wipe down the mating surfaces of the cylinder head and the manifold with brake system cleaner and inspect the manifold with a straightedge, any warpage will require replacement. Install new gaskets and O-rings on the receiver grooves on the manifold, mount the manifold on the engine, and install the bolts. Install the fasteners with three or four similar force to the given specification, moving towards the ends through the center to prevent warping of the manifold. Install the rest of the parts in the reverse sequence of the sequence of removal, and a new O-ring in the bottom of the dipstick tube should be installed in case it was fully removed, and lubricated with clean engine oil. Check throttle linkage to operate easily before starting the engine, refill and bleed the cooling system and run the engine to check on the coolant and vacuum leakage.