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Discussion Starter #1
Need to know what holds this box on and where all the bolts are located. I've got a nice vacuum leak inside here and would like to get this fixed
 

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Monkey Slut!
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Intake manifold is going to be fun, if I remember correctly it should be 2 bolts per port so a total of 10 bolts maybe 12. Some you might have to get through the wheel well. They are held on with a washer so you don't have to worry about dropping them. Good luck.
 

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Note: This is for the 3.7L, but the 3.5 should be similar.

Intake Manifold Replacement

Removal Procedure



  1. Remove the throttle body. Refer to Throttle Body Assembly Replacement.
  2. Remove the battery box. Refer to Battery Box Replacement.
  3. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
  4. Disconnect the brake booster hose (6) from the brake booster.
  5. Disconnect the engine wiring harness electrical connector (3) from the manifold absolute pressure (MAP) sensor.
  6. Disconnect the engine wiring harness retainer (4) from the intake manifold (5).
  7. Disconnect the positive crankcase ventilation (PCV) dirty air tube (2) from the camshaft cover.
  8. Remove the generator. Refer to Generator Replacement.
  9. Disconnect the engine wiring harness retainer (1) from the intake manifold (2).
  10. Remove the upper 2 bolts securing the engine wiring harness bracket to the intake manifold.
  11. Raise and support the vehicle only high enough to access the remaining components through the wheelhouse. Refer to Lifting and Jacking the Vehicle.
  12. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation.
  13. Remove the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
  14. Disconnect the following wiring harness retainers from the engine wiring harness bracket:
    • The battery cable
    • The engine (4, 6)
    • The MAP sensor (5)
  15. Remove the remaining engine wiring harness bracket lower bolt. Remove the bracket from the engine compartment through the wheelhouse opening.
  16. Remove the intake manifold bolts.
  17. Lower the vehicle.
  18. Remove the intake manifold from the cylinder head.
  19. Remove and discard the seal from the intake manifold. Discard the seal.
  20. Mask off the open ports to the cylinder head, in order to prevent foreign objects from entering the engine.

Installation Procedure


  1. Remove the masking from the cylinder head and ensure the sealing surface is clean and dry.
  2. Install a NEW seal into the intake manifold groove.
  3. Position the intake manifold to the cylinder head.
  4. Raise and support the vehicle only high enough to access the following components through the wheelhouse Refer to Lifting and Jacking the Vehicle.
    • The intake manifold bolts
    • The engine wiring harness bracket bolts
    • The wiring harnesses
    Caution: Refer to Fastener Caution in the Preface section.
  5. Install the intake manifold bolts and tighten from the inside working outward to 10 N·m
    (89 lb in)
    .
  6. Position the engine wiring harness bracket to the engine.
  7. Install the engine wiring harness bracket bolts and tighten to 10 N·m (89 lb in).
  8. Secure the following wiring harness retainers to the bracket:
    • The battery cable
    • The engine (4, 6)
    • The MAP sensor (5)​
  9. Install the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
  10. Install the left front wheel. Refer to Tire and Wheel Removal and Installation.
  11. Lower the vehicle.
  12. Connect the engine wiring harness retainer (1) to the intake manifold (2).
  13. Install the generator. Refer to Generator Replacement.
  14. Connect the PCV dirty air tube (2) to the camshaft cover.
  15. Connect the engine wiring harness retainer (4) to the intake manifold (5).
  16. Connect the engine wiring harness electrical connector (3) to the MAP sensor.
  17. Connect the brake booster hose (6) to the brake booster.
  18. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
  19. Install the battery box. Refer to Battery Box Replacement.
  20. Install the throttle body. Refer to Throttle Body Assembly Replacement.
 

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Intake manifold is going to be fun, if I remember correctly it should be 2 bolts per port so a total of 10 bolts maybe 12. Some you might have to get through the wheel well. They are held on with a washer so you don't have to worry about dropping them. Good luck.
I think you're right on the 10 bolts.

Also, to make life easier, remove battery and battery box,
Alternator (some have been able to get those hidden bolts with out removing it), A couple of engine harnesses/brackets, power brake hose, crankcase vent hose, some have to remove oil dipstick, I didn't tho.
There may be more but that's what I remember.
 

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I shudda just waited a few minutes, rshadd sure does state it better. Nice pictures too.
 

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Discussion Starter #9
Thanks for all the replies guys! Rich chimed in with exactly what I needed. The pcv hose that is coming out of the back has a pretty good leak in it. Is there any way that I can replace just the hose? If so, how can I go about doing that?
 

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Before you get involved with the intake I would first check the PCV tube for leaks.


Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Removal Procedure

  1. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement.
  2. Disconnect the PCV fresh air tube (6) from the air cleaner resonator (1).
  3. Disconnect the PCV dirty air tube (2) from the following:
    • The camshaft cover (5)
    • The intake manifold (3)

Installation Procedure



  1. Connect the PCV fresh air tube (6) to the air cleaner resonator (1).
  2. Connect the PCV dirty air tube (2) to the following:
  3. Install the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement.
    • The camshaft cover (5)
    • The intake manifold (3)
 

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Discussion Starter #13

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Discussion Starter #16
Okay, yeah that hose isn't easy to replace. You have to take apart the intake manifold cover and you might end up breaking it so beware. It snaps together and has clips all the way around it that are a pain to take apart.
I might give that a shot because I don't want to buy a whole new intake manifold. What should I do to release those clips ??

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Monkey Slut!
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I had to use two flat head screwdrivers and still ended up breaking it. You'll see once you have it pulled off, just go slow. There is a few that attache the over to the actual intake, those will be tricky. I had an extra one at the time so it didn't matter if I broke it or not.
 

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tinja nurtles
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You could always take the easy way and break the cover around where the hose connects. Then make a patch to cover it once you are done if you don't like the hole.

A member near me did that
 

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Discussion Starter #20
I had to use two flat head screwdrivers and still ended up breaking it. You'll see once you have it pulled off, just go slow. There is a few that attache the over to the actual intake, those will be tricky. I had an extra one at the time so it didn't matter if I broke it or not.
I think I'll do that. But a cover just in case as well as a hose to replace the broken one. Thanks!

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