Lower Intake Manifold

Lower Intake Manifold

Removal
1. Drain the engine cooling system.
2. Remove both the valve covers.





3. Disconnect the engine control sensor wiring.
- Disconnect the Crankshaft Position (CKP) sensor.
- Disconnect the Engine Coolant Temperature (ECT) sensor.
- Disconnect the water temperature indicator sender.
- Disconnect the fuel injectors.
- Disconnect the Camshaft Position (CMP) sensor.
4. Relieve the fuel pressure and disconnect the fuel line.





5. Remove the fuel injection supply manifold and the fuel injector as an assembly.
- Remove four bolts.
6. Disconnect the upper radiator hose.





7. Disconnect the bypass hose.





8. Loosen the bolt for the rocker arm at the number three cylinder intake valve.
9. Remove the push rod for the number three cylinder intake valve.





10. Remove the bolts from the lower intake manifold.





11. NOTE: Gently loosen the intake manifold to separate the silicone sealant from the cylinder block.

Remove the lower intake manifold.





12. Remove and discard the intake manifold gaskets and end seals.

Installation





1. Clean all the sealing surfaces.





2. NOTE: If the lower intake manifold is not installed within four minutes, remove the sealant and reapply.

Install the intake manifold gaskets and seals.
1 Apply a drop of silicone gasket and sealant at the four cylinder block-to-cylinder head seams.
2 Position the intake manifold gaskets.
3 Position the intake manifold front and rear seals.





3. Position the lower intake manifold.





4. Install the bolts and tighten in the sequence shown.
5. Install the push rod for the number three cylinder intake valve.





6. Tighten the rocker arm.





7. Connect the bypass hose.
8. Connect the upper radiator hose.





9. Install the fuel injection supply manifold and the fuel injectors as an assembly.
- Position the fuel injection supply manifold.
- Install the four bolts.
10. Connect the fuel line.





11. Connect the engine control sensor wiring.
- Connect the Crankshaft Position (CKP) sensor.
- Connect the Engine Coolant Temperature (ECT) sensor.
- Connect the water temperature indicator sender.
- Connect the fuel injectors.
- Connect the Camshaft Position (CMP) sensor.
12. Install both valve covers.
13. Fill and bleed the engine cooling system.