Intake Manifold Assembly

Intake Manifold Assembly




Material

Disassembly





1. NOTE: LH side shown, RH side similar.

Remove the four fuel rail bolts.





2. Remove the bolts from the Fuel Pressure Regulator (FPR).
^ Remove the fuel rail and injectors as an assembly.





3. Remove the fuel injectors from the fuel rail.





4. Remove and discard the O-ring seals from each fuel injector.





5. Separate the upper and lower intake manifolds.
^ Remove the bolts.
^ Discard the intake manifold gasket.
6. Using a metal surface prep, clean and inspect the upper and lower manifold internal passengers and mating surfaces.
7. Allow the upper and lower intake manifolds to dry completely.

Assembly





1. Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.





2. Tighten the bolts in two stages, using the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





3. Install new O-ring seals on each fuel injector.





4. CAUTION: Check for fuel leakage after installation is complete.

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

Install the fuel injectors into the fuel rail.





5. Position the fuel rail. Install the bolts for the FPR sensor.





6. NOTE: LH side shown, RH similar.

Install the four fuel rail bolts.