Intake Manifold Lower Removal/Installation

INTAKE MANIFOLD LOWER REMOVAL/INSTALLATION

1. Drain the engine cooling system.
2. Remove both valve covers. See VALVE COVER-RH REMOVAL/INSTALLATION and VALVE COVER-REMOVAL/INSTALLATION.




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. Relieve the fuel system pressure and disconnect the fuel line. See FUEL LINE AND VAPOR LINE QUICK DISCONNECT FITTINGS.




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.

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




13. Remove the lower intake manifold.




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

Installation

NOTE: Clean and inspect all mating surfaces.

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




1. Install the 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 the intake manifold gaskets.
3. Position the intake manifold front and rear seals.




2. Position the lower intake manifold.




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




5. Tighten the rocker arm

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




6. 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 line.




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.