Lower Intake Manifold

LOWER INTAKE MANIFOLD

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.

NOTE: Turbo charged engines could be equipped with either an aluminum or a plastic intake manifold.

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.








9. Remove screw attaching the oil dipstick tube to lower intake manifold (Fig. 148) or (Fig. 149).
10. Turbocharger Equipped Engine: Remove fasteners for lower intake manifold support bracket (Fig. 149).





11. Remove lower intake manifold fasteners (Fig. 154).
12. Remove lower intake manifold.

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

INSPECTION
1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary.
2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary.

LOWER INTAKE MANIFOLD

NOTE: Turbo charged engines could be equipped with either an aluminum or a plastic manifold.

1. Clean all gasket surfaces.





2. Naturally Aspirated Engine: Position new seals on lower intake manifold. (Fig. 153).





3. Naturally Aspirated Engine: Install lower intake manifold. Tighten fasteners to 12 Nm (105 inch lbs.) in sequence shown in (Fig. 154).
4. Turbocharged Engine: Replace lower intake manifold gasket.
5. Turbocharged Engine: Install lower intake manifold. If equipped with an aluminum manifold, tighten fasteners to 28 Nm (250 inch lbs.) in sequence shown in (Fig. 154).If equipped with a plastic manifold, tighten fasteners to 12 Nm (105 inch lbs.) in sequence shown in (Fig. 154)
6. Turbocharger Equipped Engine: Install fasteners for lower intake manifold support bracket (Fig. 149). If equipped with an aluminum manifold, torque fasteners to 54 Nm (40 ft. lbs.). If equipped with a plastic manifold, torque manifold fasteners to 6 Nm (55 inch lbs.).
7. If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 inch lbs.).
8. Connect fuel injector wiring harness.
9. 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.
10. Install the screw attaching the oil dipstick tube to lower intake manifold (Fig. 148) or (Fig. 149).
11. Install coolant outlet connector and thermostat.
12. Install radiator upper hose.
13. Install upper intake manifold.
14. Connect negative cable to battery.
15. Fill the cooling system
16. 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.