Lower Intake Manifold Assembly Replacement

REMOVAL
1. Remove the upper intake manifold.
2. Remove the fuel rail. See Powertrain Management.
3. Disconnect the radiator hose from the thermostat housing. See Cooling System.
4. Disconnect the electrical connection at the temperature sensor.
5. Remove the heater pipe nut at the throttle body.
6. Remove the lower intake manifold mounting bolts.
7. Remove the lower intake manifold.
8. Remove the lower intake manifold gaskets.
9. Clean the gasket material from the mating surfaces.

INSTALLATION
1. Install the lower intake manifold gaskets.
2. Install the lower intake manifold.
3. Install two M8 x 1.25 x 50 mm bolts with washers to the vertical holes in the intake manifold. Tighten the bolts to 7 Nm (62 inch lbs.).
4. Installing the bolts in the vertical holes of the manifold will align the intake bolt grommet bores with the threaded holes in the cylinder heads. This will minimize the possibility of crossthreading and damage to the grommets resulting in a leak at the intake manifold Gaskets.
5. Install the lower intake manifold mounting bolts. Insert rubber isolators fully into the manifold mounting flange before tightening any fasteners.
6. Draw the lower intake manifold in place by tightening the bolts gradually, starting with the middle bolts and working in a circular pattern. Do not tighten one side or one end fully. Tighten the bolts to 13 Nm (116 inch lbs.).
7. Remove the two bolts in the vertical holes of the intake manifold.
8. Install the heater hose pipe nut at the throttle body.
9. Connect the electrical connection at the temperature sensor.
10. Connect the radiator hose to the thermostat housing. See Cooling System.
11. Install the fuel rail. See Powertrain Management.
12. Install the upper intake manifold.