Lower Intake Manifold

INTAKE MANIFOLD LOWER

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

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

3. Disconnect fuel line.
4. Drain the cooling system.
5. Remove heater supply and radiator upper hoses at intake manifold.
6. Disconnect coolant temperature sensor/fuel injector wire harness connector.

Fig.109:

7. Remove lower intake manifold support bracket upper bolts (Fig. 109).
8. Loosen the lower intake manifold support bracket lower bolt (Fig. 109).
9. Disconnect fuel injector harness.
10. Remove the bolts attaching the power steering reservoir to manifold. Set reservoir aside. Do not disconnect line from reservoir.

Fig.110:

11. Remove lower intake manifold fasteners (Fig. 110). Remove the manifold from engine.
12. Inspect the manifold.

INSPECTION
1. Check manifold surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 inch per foot) of manifold length.
2. Inspect manifold for cracks or distortion. Replace manifold if necessary.

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

1. Position a new gasket on cylinder head and install lower manifold.
2. Install and tighten intake manifold fasteners to 28 Nm (250 in. lbs.) in the sequence shown in (Fig. 110). Repeat procedure until all bolts are at specified torque.
3. Install lower intake manifold support bracket bolts (Fig. 109) and tighten to:
- Bolts to intake 28 Nm (250 in. lbs.)
- Bolt to engine block 54 Nm (40 ft. lbs.)

4. Position power steering reservoir on manifold and install bolts.
5. Connect the fuel line.
6. Connect coolant temperature sensor/fuel injector wiring harness electrical connector.
7. Install the radiator upper and heater supply hoses.
8. Install the upper intake manifold.
9. Fill the cooling system.