Lower

Intake Manifold-Lower

Removal
1. Drain the engine cooling system.
2. Remove the upper intake manifold.
3. Disconnect the fuel lines.





4. Disconnect the engine water bypass hose.





5. Disconnect the electrical connector from the water temperature indicator sender.





6. Disconnect the upper radiator hose, the heater water inlet hose and the heated positive crankcase ventilation (PCV) water heated fitting inlet hose.





7. Remove the four bolts and the upper generator support bracket.





8. Disconnect the eight fuel injectors.





9. Disconnect the vacuum line from the fuel injector pressure regulator and position out of the way.





10. Remove the bolts and lower intake manifold.





11. Remove the bolts and the radio ignition interference capacitors.





12. Remove and inspect the gaskets, install new gaskets if necessary.





13. Clean the sealing surfaces.

Installation





1. Install the radio ignition interference capacitors.





2. NOTE: Bolts should be hand-started, positions 7-12 first then 1-6.

Install the lower intake manifold:
^ Position the gaskets.
^ Install the intake manifold.
^ Install the bolts.
^ Tighten the bolts to 10 Nm (89 inch lbs.) and then an additional 90 degrees in the sequence shown.





3. Connect the water temperature indicator sensor.





4. Position the vacuum harness and connect the vacuum line to the fuel injector pressure regulator.





5. Connect the eight fuel injectors.





6. Install the upper generator support bracket and the four bolts.





7. Connect the heater water inlet hose, the upper radiator hose and the water heated fitting inlet hose.





8. Connect the engine water bypass return hose.
9. Connect the fuel lines.
10. Install the upper intake manifold.