Intake Manifold Assembly - Disassembly and Assembly

Intake Manifold Assembly













Disassembly

1. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will ease removal of the fuel rail.

Remove the 4 bolts, separate the fuel rail from the 10 fuel injectors and remove the fuel rail.

2. Remove the fuel injectors from the intake manifold and discard the upper and lower fuel injector O-ring seals.

3. Separate the upper and lower intake manifolds.
- Remove the 10 bolts.

- Discard the intake manifold gaskets.

4. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Inspect all external and internal surfaces of the intake manifold.

- Inspect for cracks or other damage.

- Inspect for foreign material inside of the manifold.

- Clean the intake manifold sealing surfaces.

Assembly

1. Position 11 new lower intake manifold gaskets and the upper intake manifold on the lower intake manifold and loosely install the 10 bolts.





2. Tighten the 10 bolts in 2 stages, using the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 10 Nm (89 lb-in).





3. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak.

NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.

Install 2 new O-ring seals on each of the 10 fuel injectors.

4. Install the 10 fuel injectors into the intake manifold.

5. Position the fuel rail onto the fuel injectors and install the 4 bolts.
- To install, tighten to 10 Nm (89 lb-in).