Lower Intake Manifold

LOWER INTAKE MANIFOLD

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

1. Perform fuel system pressure release procedure before attempting any repairs.
2. Disconnect negative battery cable.
3. Remove upper intake manifold.
4. Partially drain cooling system below thermostat level.
5. Remove upper radiator hose.
6. Remove coolant outlet connector and thermostat.
7. Disconnect the fuel supply line quick connect at the fuel rail assembly.

WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.

8. Disconnect fuel injector wiring harness.

Fig. 147:

9. Remove screw attaching the oil dipstick tube to lower intake manifold (Fig. 147).

Fig. 152:

10. Remove lower intake manifold fasteners (Fig. 152).
11. Remove lower intake manifold.

CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.

INSPECTION
1. Inspect manifold for cracks or distortion. Replace manifold if necessaly.
2. Inspect manifold for gasket surface damage or warpage. Replace manifold if necessaly.

INSTALLATION
1. Clean all gasket surfaces.

Fig. 151:

2. Position new seals on lower intake manifold, if replaced (Fig. 151).
3. Install lower intake manifold. Tighten fasteners to 12 Nm (105 in. lbs.) in sequence shown in (Fig. 152).
4. If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 in. lbs.).
5. Connect fuel injector wiring harness.
6. Inspect quick connect fittings for damage, replace if necessary. Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly Check connection by pulling on connector to insure it locked into position.
7. Install the screw attaching the oil dipstick tube to lower intake manifold (Fig. 147).
8. Install coolant outlet connector and thermostat.
9. Install radiator upper hose.
10. Install upper intake manifold.
11. Connect negative cable to battery.
12. Fill the cooling system.
13. With the DRBIII scan tool use ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.