Lower

* THIS ARTICLE REFLECTS CHANGES MADE BY TSB #94-18-10, DATED September 07, 1994


REMOVAL

NOTE: The intake manifold is a four piece assembly consisting of the upper intake manifold, the throttle body, the fuel supply manifold and the lower intake manifold.

1. Disconnect the battery ground cable at the battery.
2. Remove the air cleaner air intake duct from the throttle body.
3. Remove the snow/ice shield and disconnect the throttle cable and bracket assembly.
4. Disconnect all vacuum hoses from the fittings on the upper intake manifold.
5. Disconnect the electrical connections at the throttle body, upper intake manifold, lower intake manifold and injectors.
6. Relieve fuel system pressure.
7. Disconnect the fuel supply and return lines at the fuel supply manifold.

Coil Mounting Bracket:

8. Remove the bolts securing the ignition coil pack and bracket assembly to the upper intake manifold.
9. Remove the six nuts securing the upper intake manifold and remove the upper manifold.
10. Remove the valve rocker arm covers.
11. Remove the intake manifold attaching bolts and nuts. Tap the intake manifold lightly with a plastic mallet to break the gasket seal, and lift off the intake manifold assembly.
12. Remove all old gasket material, and sealing compound.

INSTALLATION

Lower Intake Manifold:

1. Apply Silicone Sealer (Loctite 598, F1AZ-19562-A or equivalent) to the block and cylinder head mating surfaces at the four corners shown. Install the intake manifold gaskets and again apply sealer to the four corner locations.

NOTE: Once applied, the silicone sealer will set-up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied.

Lower Intake Manifold Bolt Tightening Sequence:

2. Position the intake manifold on the two guide studs and install the nuts and bolts hand tight. Tighten the intake manifold bolts in four stages following the sequence shown.
a. 4-8 Nm (3-6 ft lb)
b. 8-15 Nm (6-11 ft lb)
c. 15-21 Nm (11-15 ft lb)
d. 21-25 Nm (15-18 ft lb)
3. Apply Silicone Sealer (Loctite 598, F1AZ-19562-A or equivalent) to the four locations at the joint where the intake manifold and cylinder heads meet.
4. Position valve rocker arm cover gasket in each cover and install valve rocker arm covers. Tighten rocker arm cover bolts evenly to 6-8 Nm (4.5-5.9 ft lb).

NOTE: Valve rocker arm covers are tightened in 2 steps. Tighten bolts to specification. Two minutes later, tighten bolts to the same specification.

Upper Intake Manifold:

5. Install upper intake manifold and tighten nuts to 20-25 Nm (15-18 ft lb).
6. Install the ignition coil pack and bracket assembly.
7. Connect the fuel supply and return lines at the fuel supply manifold.
8. Connect the electrical connections at the throttle body, upper intake manifold, lower intake manifold and injectors.
9. Connect all vacuum hoses to the fittings on the upper intake manifold.
10. Install the throttle cable and bracket assembly and the snow/ice shield to the throttle body.
11. Connect the air cleaner air intake duct to the throttle body.
12. Fill and bleed the cooling system.
13. Connect the battery ground cable at the battery.
14. Check for fuel system and oil leaks.