Lower Intake Manifold

Lower Intake Manifold





Material

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





3. Disconnect the upper radiator hose, heater hose and coolant bypass hose.





4. Disconnect the engine coolant temperature (ECT) sensor and coolant temperature sender electrical connectors.





5. Disconnect the crankshaft position (CKP) sensor and detach the wiring from the stud bolt.
6. Disconnect the fuel injector electrical connectors and position the engine control wiring aside.
7. Release the fuel pressure and disconnect the fuel tube.





8. Remove the four bolts and the fuel injection supply manifold and fuel injectors as an assembly.





9. Remove the fuel injectors from the fuel supply manifold.
- Remove and discard the fuel injector O-ring seals.





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





12. Remove the bolts from the lower intake manifold.





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

Remove the lower intake manifold.





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

Installation





1. NOTE: Clean and inspect all mating surfaces.

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

Install new 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 new intake manifold gaskets.
3. Position new intake manifold front and rear seals.





2. Position the lower intake manifold.





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





5. Tighten the rocker arm.





6. NOTE: Lubricate the new O-ring seals with clean engine oil.

Install new O-ring seals on the fuel injectors and install the fuel injectors.





7. Install the fuel injection supply manifold and the fuel injectors as an assembly.
- Position the injectors and the fuel injection supply manifold.
- Install the four bolts.
8. Connect the fuel tube.





9. Connect the fuel injector electrical connectors.





10. Connect the crankshaft position (CKP) sensor and attach the wiring from the stud bolt.





11. Connect the engine coolant temperature (ECT) sensor and coolant temperature sender electrical connectors.





12. Connect the upper radiator hose, heater hose and coolant bypass hose.
13. Install both valve covers.
14. Fill and bleed the engine cooling system.