Page 2857 of 6020

Engine Mechanical – V6 Page 6A1–80
Page 6A1–80
13 Disconnect the EVAP valve outlet tube (1) from the
intake manifold (2).
14 Remove the four long (3) (165 mm long) and two short bolts (4) (70 mm long) attaching the upper intake
manifold (2) to the cylinder heads and lower intake
manifold.
15 Lift the upper intake manifold (2) clear from the lower half and then remove the upper intake manifold from
the engine.
16 Remove and discard the upper to lower intake manifold gaskets (5).
• When the upper intake manifold is
removed, plug each of the lower intake
runner openings with lint free cloth, to
stop the entry of forei gn material into the
engine.
• Do not reuse the upper to lower intake
manifold gaskets (5).
Figure 6A1 – 40
17 Remove the upper and lower intake manifold assembly from the engine.
18 Remove lower intake mani fold to cylinder head gasket.
Disassemble
Remove the following from the upper intake manifold, refer to Section 6C1-3 Engine Management – V6 – Service
Operations :
• BARO sensor and
• Throttle body assembly.
Clean
CAUTION
Due to the aluminium alloy construction of
the intake manifold, wire brushes and steel
scrapers must not be used during the
cleaning process, as damage to sealing
surfaces may occur. Use of a wooden or
plastic scraper is preferred.
1 Clean mating surfaces ensuring any gasket material is removed.
2 Clean the manifold using a suitable solvent.
Safety glasses must be worn when using
compressed air.
3 Dry the timing components with compressed air.
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Page 2858 of 6020

Engine Mechanical – V6 Page 6A1–81
Page 6A1–81
Inspect
1 Inspect the intake manifold for the following fault conditions:
• Damaged sealing and mating surfaces.
• Damaged lower intake manifold gasket.
• Damage or excessive debris on the threaded and through holes.
• Cracks or damage to the intake manifold body.
NOTE
If the lower intake manifold is cracked or
damaged, it must be repl aced. No welding or
patching of the intake manifold should be
performed.
2 Place a straight edge (1) across the upper intake manifold sealing surface (2).
3 Using a feeler gauge (3), measure the clearance
between the manifold and the straight edge.
4 If the clearance between the upper intake manifold sealing surface and the straight edge exceeds the
specified maximum warpage, replace the manifold.
Upper manifold maximum
warpage ............................................................ 0.05 mm
Figure 6A1 – 41
5 Place a straight edge (1) across the lower intake manifold sealing surface (2).
6 Using a feeler gauge (3), measure the clearance
between the manifold and the straight edge.
7 If the clearance between the lower intake manifold sealing surface and the straight edge exceeds the
specified maximum warpage, replace the manifold.
Lower manifold maximum
warpage ............................................................ 0.05 mm
Figure 6A1 – 42
Reassemble
Reassembly of the upper manifold is the reverse of the disassembly procedure .
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Page 2859 of 6020

Engine Mechanical – V6 Page 6A1–82
Page 6A1–82
Reinstall
Reinstallation of the upper intake manifold and the upper and lower intake manifold assembly is the reverse of the
removal procedure, noting the following:
1 Only new gaskets are to be fitted betw een the upper and lower intake manifolds.
CAUTION
Tighten the intake manifold bolts in a circular
pattern starting at the centre bolt and moving
outward.
2 Ensure that all fasteners are tightened to the correct torque specification.
Upper intake manifold to lower
intake manifold attaching bolt
torque specificat ion ............................................ 23.0 Nm
Upper intake manifold to
cylinder head attaching bolt
torque specification ............................................ 23.0 Nm
Incorrect wiring connector installation may
cause component malfunction or component
damage.
3 Ensure all wiring connectors are fully engaged and if applicable, locked in place.
4 Ensure all wiring harnesses are correctly routed and attached securely in their retaining clips.
5 Ensure that all hoses and pipes ar e routed correctly and that any retaining clips are correctly installed.
6 Start and run the engine to c heck for correct operation.
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Page 2860 of 6020
Engine Mechanical – V6 Page 6A1–83
Page 6A1–83
3.10 Intake Manifold Assembly – Complete
The intake manifold comprises of an upper and lower section. Some service procedures only require the removal of the
upper intake manifold (e.g. fuel injector/spark plug servicing), while other servic e procedures require the removal of both
the upper and lower manifold as a complete assembly (e.g . cylinder head/s). If only the upper intake manifold needs to
be removed, refer to 3.9 Upper Intake Manifold .
Remove
Disconnection of the battery affects
certain vehicle electronic systems. Refer to
1.1 WARNING, CAUTION and NOTES before
disconnecting the battery.
1 Depressurise the fuel system.
2 Disconnect the battery negative terminal.
3 Remove the air intake duc t (1) and hose (2), refer to
Section 6C1-3 Engine Management – V6 – Service
Operations .
Figure 6A1 – 43
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Page 2861 of 6020

Engine Mechanical – V6 Page 6A1–84
Page 6A1–84
4 Retract the throttle body wiring connector lock (3).
5 While pressing the connector latch in the direction of
the arrow (4), disconnect the throttle body wiring
connector.
6 Disconnect the throttle body connector wiring harness from its retaining clip (5).
7 Remove the main wiring harness retainer pin (6) from the intake manifold by pushing from the front to the
rear using a suitable piece of 5 mm steel rod (or an
Allen key).
The following precautions must be followed
when disconnecting the throttle body wiring
connector:
• Do not use any mechanical device such
as a screwdriver to disengage the
harness connector (1) from the throttle
body (2).
• When retracting the throttle wiring
connector lock (3), take care not to
disengage the lock from the connector.
• Do not pull on the connector wires.
• Take care not to break the barbed
harness retainer pin (6) while removing
the harness retainer from the intake
manifold.
• Should the pin be broken, then it is vital
that a new harness retainer is fitted to the
wiring harness shield. If not, the harness
will foul the engine drive belt.
Figure 6A1 – 44
8 Disconnect the brake booster hose (1), from the upper
intake manifold:
Figure 6A1 – 45
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Page 2862 of 6020
Engine Mechanical – V6 Page 6A1–85
Page 6A1–85
9 Disconnect the wiring harness connector from the
barometric (BARO) pressure sensor (1).
Figure 6A1 – 46
10 Disconnect the PCV tube connector (1) from the upper intake manifold assembly.
Figure 6A1 – 47
11 Disconnect the fuel feed hose from the fuel rail (1).
12 Pull out the release bar (2) (broad arrow) of the fuel
injector harness wiring connector (3).
13 Disconnect the fuel injector harness wiring connector from the fuel injector wiring harness (4).
Plug the fuel feed hose opening after
removal to prevent dirt and other
contaminants from entering the fuel system.
Figure 6A1 – 48
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Page 2863 of 6020

Engine Mechanical – V6 Page 6A1–86
Page 6A1–86
14 Remove the wiring harness connector (2) from the
EVAP valve (1).
15 Disconnect the quick connect (3 ) from the rear of the
EVAP valve, as follows:
a Squeeze the two barbed lugs together, push the quick
connect into the valve, t hen pull out to separate the
connection.
b Plug both open ends to prevent the entry of foreign
matter.
Figure 6A1 – 49
16 Remove the bolt (3) attaching the EVAP valve and the fuel injector wiring harness connector mounting
bracket to the upper inta ke manifold assembly.
17 Move the EVAP valve and the fuel injector wiring harness connector mounting bracket clear of the
upper intake manifold assembly.
18 Disconnect the PCV fresh air tube (1) from its upper intake manifold mounting clip (2).
Figure 6A1 – 50
19 Remove the four long (1) bolts (165 mm) securing the complete intake manifo ld to the cylinder heads.
20 Remove the two short (2) bolts (45 mm) securing the lower intake manifold to the cylinder heads.
Do not loosen nor remove the short bolts ( 8)
(70 mm) holding the upper intake manifold to
the lower. These bolts are at the front left
and rear right of the upper intake manifold.
Figure 6A1 – 51
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Page 2864 of 6020

Engine Mechanical – V6 Page 6A1–87
Page 6A1–87
When the intake manifold is removed, plug
each of the cylinder head intake openings
with lint free cloth, to stop the entry of foreign
material into the intake ports.
21 Remove the upper and lower intake manifold assembly from the engine.
22 Remove lower intake mani fold to cylinder head gasket.
Disassemble
1 Disconnect the EVAP hose (1) from the upper intake
manifold (2).
2 Remove the bolts (3) (70 mm long) attaching the upper intake manifold to the lower intake manifold (4).
NOTE
These bolts are located at the front left and rear
right of the upper intake manifold, as shown.
3 Remove the upper intake manifold from the lower intake manifold.
4 Remove and discard the upper to lower intake manifold gaskets.
Do not reuse the upper to lower intake
manifold gaskets (5).
5 Remove the EVAP hose from the retaining clip (6) attached to the lower intake manifold.
6 Remove the following from the upper intake manifold, refer to Section 6C1-3 Engine Management – V6 –
Service Operations :
• BARO Sensor and
• Throttle Body assembly
Figure 6A1 – 52
7 Remove the fuel rail and in jector assembly. Refer to
Section 6C1-3 Engine Management – V6 – Service
Operations .
The following precautions must be followed
when removing the fuel rail and injector
assembly:
• Care must be taken when removing the
fuel rail and injector assembly to
prevent damage to the injector spray
tips and injector harness connector
terminals.
• Support the fuel rail and injector
assembly after removal.
• Plug all fuel line and manifold openings
after removal to prevent dirt and other
contaminants from entering the fuel
system.
Figure 6A1 – 53
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