Lower Intake Manifold

Lower Intake Manifold

Removal

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Partially drain the cooling system.
2. Remove the upper intake manifold.
3. Remove the fuel injection supply manifold.





4. Disconnect the exhaust gas recirculation (EGR) vacuum hose.





5. Loosen the nut and disconnect the EGR-to-exhaust manifold tube.





6. Disconnect the heater hose.





7. Disconnect the upper radiator hose.





8. Disconnect the intake manifold runner control (IMRC) electrical connector.





9. Position the water bypass tube aside.
1. Remove the bolts.
2. Position the tube aside.





10. NOTE: Note the location of the six long bolts for installation. Remove the lower intake manifold.

1. Remove the bolts.
2. Remove the intake manifold.
11. Remove the intake manifold runner control (IMRC) if necessary.





12. Remove and discard the lower intake manifold sealing components.
13. Clean gasket sealing surfaces with metal surface cleaner.

Installation





1. Refer to the illustration for intake manifold sealing component locations.





2. Install the lower intake manifold front and rear end seals.
1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as shown.
2. Install the lower intake manifold front and rear end seals.





3. Install the intake manifold gaskets.





4. NOTE: The lower intake manifold must be installed within four minutes of applying sealant.

Position the lower intake manifold.
1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points shown.
2. Position the lower intake manifold.





5. NOTE: Make sure the bolts are installed in the correct locations.

Install the six long bolts.





6. Install the eight short bolts.





7. Tighten the lower intake manifold bolts in two stages in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten to 10 Nm (89 inch lbs.).
8. Install the intake manifold runner control (IMRC) if required.





9. Connect the water bypass tube.
1. Position the tube.
2. Install the bolts.





10. Connect the intake manifold runner control (IMRC) electrical connector.





11. Connect the upper radiator hose.





12. Connect the heater hose.





13. Connect the EGR-to-exhaust manifold tube.





14. Connect the EGR vacuum hose.
15. Install the fuel injection supply manifold.
16. Install the upper intake manifold.
17. Fill and bleed the cooling system.