Lower Manifold Replacement

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

To release fuel pressure, refer to Powertrain Management for procedure.

REMOVAL
1. Perform fuel system pressure release procedure before attempting any repairs.
2. Remove upper intake manifold.

CAUTION: Cover intake manifold to prevent foreign material from entering engine.

Intake Air Temperature Sensor:

3. Disconnect electrical connector from intake air temperature sensor.

Fuel Line Quick Disconnect:

4. Remove fuel hose quick connect fitting from the chassis tube.

WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

5. Drain cooling system.
6. Remove heater, and upper radiator hoses at intake manifold.

Coolant Temperature Sensor-2.4L:

7. Disconnect coolant temperature sensor.
8. Remove the accessory drive belt.
9. Remove fasteners attaching generator bracket to cylinder head, and block.

Intake Manifold Center Support Bracket:

10. Remove intake manifold center support bracket bolts (Y bracket).
11. Disconnect fuel injector harness.

Intake Manifold Fasteners:

12. Remove lower intake manifold fasteners. Remove the manifold from engine.
13. Inspect and clean manifold. Refer to Cleaning and Inspection for procedures.

INSTALLATION
If the following items were removed, install and torque to:
- Fuel rail bolts 22 Nm (200 inch lbs.)
- Engine outlet connector bolts 28 Nm (250 inch lbs.)
- Coolant temperature sensor 7 Nm (60 inch lbs.)
- Intake air temperature sensor 28 Nm (250 inch lbs.)

1. Using a new intake gasket, position intake manifold on the engine and install retaining bolts.
2. Tighten intake manifold fasteners in the following sequence. Torque to 23 Nm (200 inch lbs.). Repeat this procedure until all bolts are at specified torque.
3. Install intake manifold center support bracket bolts (Y bracket) and tighten to:
- Fastener to block 54 Nm (40 ft. lbs.)
- Fastener to intake 28 Nm (250 inch lbs.)

4. Install fuel hose quick connect fitting to chassis tubes. Push the fitting onto the chassis tube until it clicks into place. Pull on the fitting to ensure complete insertion.
5. Connect fuel injector harness.
6. Install generator bracket to cylinder head and block.
7. Install accessory drive belt.
8. Connect coolant temperature sensor electrical connector.
9. Install upper radiator and heater hoses.
10. Fill cooling system.
11. Connect intake air temperature sensor electrical connector.
12. Install upper intake manifold.

CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the OFF position.

13. With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.