QuestionIt appears the fire was caused by a short in the wires going to the fuel injectors on the passenger side. I see no major damage, save for the wires and the Oxygen sensor. I need to replace them but have trouble removing the air intake manifold to access them. Can you please walk me through the process of replacing those wires. Thank you!
AnswerINTAKE MANIFOLD - 3.5L ENGINE
The intake system has a large air intake plenum of aluminum alloy and a cross type intake manifold.
REMOVAL
Release fuel system pressure. Refer to Fuel System Pressure Release Procedure.
Drain cooling system. Refer to Cooling System for procedure.
Remove engine cover from top of intake manifold plenum.
Remove accelerator cable and speed control cable from throttle arm Throttle Lever - 3.5L Engine
Disconnect electrical connectors from idle air control motor, and intake air temperature Idle Air Control Motor
Remove ground screw from intake manifold.
Disconnect vacuum hose from manifold tuning valve Idle Air Control Motor
Disconnect electrical connector from manifold absolute pressure (MAP) sensor MAP Sensor
Disconnect electrical connector from throttle position sensor Throttle Position Sensor
Disconnect purge hose from throttle bodies Throttle Position Sensor
Disconnect PCV makeup air hose and idle air control motor supply hose (part of air inlet plenum) Remove air inlet plenum from behind manifold Air Inlet Plenum
Disconnect PCV hose, brake booster hose and vacuum hoses from intake manifold.
Remove EGR tube mounting bolts at intake manifold plenum EGR Tube Top Mounting Bolts Discard gaskets.
Remove air plenum support bracket bolt on each side of manifold Intake Manifold Plenum Support (Right Side)
Remove intake manifold plenum mounting bolts. The plenum uses two different length bolts Intake Manifold Plenum
Remove intake manifold plenum. Discard gaskets. Cover the intake manifold openings with tape.
Remove upper radiator hose from thermostat housing and heater hose from rear of intake manifold.
Remove intake manifold attaching bolts Intake Manifold Tightening Sequence
INSTALLATION
Install intake manifold with new gaskets. Tighten in sequence shown in Intake Manifold Tightening Sequence to 28 N·m (250 in. lbs.)
Connect upper radiator hose and heater hose at the rear of intake manifold.
Ensure that ignition cables are routed correctly so they will not be pinched when plenum is installed.
Install intake manifold plenum with new gaskets. Tighten in sequence shown in Intake Manifold Plenum to 28 N·m (250 in. lbs.)
Install and tighten support bracket bolts.
Attach electrical connectors to MAP Sensor, TPS, idle air control motor and intake air temperature sensor.
Connect vacuum hose to manifold tuning valve diaphragm.
Install EGR tube.
Rotate throttle arm to wide open throttle position and install the speed control cable and throttle cable.
Connect hose to PCV valve.
Install air cleaner plenum.
Install air cleaner to plenum hose.
Attach ground wire to intake manifold plenum.
Connect brake booster hose to fitting on intake manifold plenum.
Connect purge tubes to fittings on throttle bodies.
Install cover on intake manifold plenum.
Connect negative cable to battery.
Fill cooling system.
