Removal Procedure

Important:  The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the front and the left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

1. Remove the upper intake manifold. Refer to Intake Manifold Replacement - Upper 
2. Remove the generator brace. Refer to GENERATOR
3. Remove the drive belt tensioner with mounting bracket and the heater water bypass inlet pipe. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) 
   Fig 1: Drive Belt Tensioner With Mounting Bracket And The Heater Water Bypass Inlet Pipe

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4. Remove the exhaust gas recirculation (EGR) outlet pipe from the lower intake manifold.
   Fig 2: EGR Outlet Pipe

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5. Remove the radiator inlet hose from the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in ENGINE COOLING .
   Fig 3: Radiator Inlet Hose

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6. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
   Fig 4: Engine Coolant Temperature (ECT) Sensor Electrical Connector

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7. Remove the generator brace bracket bolts.
8. Remove the generator brace bracket.
   Fig 5: Generator Brace Bracket Bolts

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9. Remove the evaporative emissions canister purge solenoid valve.
   Fig 6: Evaporative Emissions Canister Purge Solenoid Valve

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10. Remove the lower intake manifold bolts.
11. Remove the lower intake manifold.
    Fig 7: Lower Intake Manifold Bolts

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12. Remove the lower intake manifold seals.
    Fig 8: Lower Intake Manifold Seals

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13. Remove the lower intake manifold gaskets.
    Fig 9: Lower Intake Manifold Gaskets

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14. If replacing the lower intake manifold, remove the water outlet housing bolt and stud, the water outlet housing, the gasket and the thermostat.
15. If replacing the lower intake manifold, remove the engine coolant temperature (ECT) sensor.
16. Inspect the flatness of inlet flanges.
17. Clean the lower intake manifold mating surfaces.
18. Clean the intake manifold bolts and bolt holes of adhesive compound.
    Fig 10: Thermostat

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