Lower Intake Manifold

Lower Intake Manifold





Material








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. Remove the coolant bypass tube.
2. Remove the fuel injection supply manifold.
3. Disconnect the 2 heater hoses from the lower intake manifold.
4. Release the upper radiator hose clamp and disconnect the upper radiator hose from the lower intake manifold.
5. Disconnect the IMRC electrical connector.

6. NOTE: Mark the location of the 8 short bolts and the 6 long bolts.

Remove the 8 short and the 6 long lower intake manifold bolts.
7. Remove the lower intake manifold.
8. Remove and discard the RH and LH lower intake manifold gaskets.
9. Remove and discard the front and rear lower intake manifold seals.

Installation
1. Clean all gasket sealing surfaces with metal surface cleaner.





2. NOTE: Front seal shown, rear seal similar.

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





3. Install the new intake manifold gaskets.





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

Position the lower intake manifold.
1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting points (at the front and rear seal).
2. Position the lower intake manifold.





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

Install the 6 long bolts.





6. Install the 8 short bolts.





7. Tighten the lower intake manifold bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).

8. Connect the IMRC electrical connector.
9. Connect the upper radiator hose to the lower intake manifold and install the clamp.
10. Connect the 2 heater hoses to the lower intake manifold.
11. Install the fuel injection supply manifold.
12. Install the coolant bypass tube.





13. Drain the engine oil.
^ Tighten to 26 Nm (19 ft. lbs.).

14. NOTE: Tighten the oil filter one-half turn after the gasket makes contact with oil filter housing.

Install a new engine oil filter.
15. Fill the engine with clean engine oil.