Lower Intake Manifold
Lower Intake ManifoldMaterial:
Fuel Rail and Heater and Radiator Hoses:
Lower Intake Manifold:
Removal
1. Disconnect the fuel supply spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the upper intake manifold.
3. Disconnect the fuel charging wiring harness-to-main engine wiring harness and the intake manifold runner control (IMRC) actuator electrical connectors.
4. Remove the bolts and the fuel rail, the fuel charging wiring harness and the engine vacuum hose harness as an assembly.
5. Release the clamp and disconnect the heater outlet hose.
6. Release the clamp and disconnect the upper radiator hose.
7. Release the clamp and disconnect the bypass hose.
8. Release the clamp and disconnect the heater inlet hose.
9. Remove the 6 long and 8 short bolts, the lower intake manifold, the lower intake manifold gaskets and the front and rear seals.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Using a plastic scraping tool, silicone gasket remover and metal surface prep, clean the gasket mating surfaces. Follow the directions on the packaging.
2. NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
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 indicated.
2 Install the lower intake manifold front and rear seals.
3. Install the intake manifold gaskets.
4. NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Position the lower intake manifold.
1 Apply a bead of silicone gasket and sealant to the lower intake manifold gaskets and front and rear seal junctions in 4 places as shown.
2 Position the lower intake manifold.
5. NOTE: Make sure the bolts are installed in the correct locations. The long bolts are installed in positions 1, 2, 3, 4, 11 and 12.
Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten to 5 Nm (44 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).
6. Connect the heater inlet hose and position the clamp.
7. Connect the bypass hose and position the clamp.
8. Connect the upper radiator hose and position the clamp.
9. Connect the heater outlet hose and position the clamp.
10. Position the fuel rail, the fuel charging wiring harness and the engine vacuum hose harness as an assembly and install the bolts.
^ Tighten to 10 Nm (89 lb-in).
11. Connect the IMRC actuator and the fuel charging wiring harness-to-main engine wiring harness electrical connectors.
12. Connect the fuel supply spring lock coupling.
13. Install the upper intake manifold.