Lower Intake Manifold

Lower Intake Manifold

Removal
1. Remove the intake manifold spacer assembly.





2. Disconnect the EGR valve vacuum hose.





3. Remove the EGR valve tube upper fitting.
4. Remove the radiator upper hose from the lower intake manifold.





5. Disconnect the water bypass hose and the heater water hose.

6. WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.

Disconnect the fuel lines.





7. NOTE: One shown, all similar.

Disconnect the fuel injector electrical connectors.





8. NOTE: One shown, all similar.

Disconnect the fuel injector electrical harness from the fuel injector supply manifold.





9. Disconnect the IMRC electrical connector and the fuel pressure regulator vacuum line.





10. NOTE: The fuel charging components, and IMRC are removed with the lower intake manifold.

NOTE: If the lower intake manifold is to be replaced, refer to removal of the IMRC.

Remove the (A) long lower intake manifold bolts, (B) the short lower intake manifold bolts and remove the lower intake manifold.





11. Remove and discard the lower intake manifold sealing components:
1 intake manifold gasket (LH)
2 intake manifold gasket (RH)
3 intake manifold rear end seal
4 intake manifold front end seal

Installation





1. Install the lower intake manifold front and rear end seals.
1 Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated.
2 Install the lower intake manifold front and rear end seals.





2. Install the intake manifold gaskets.





3. NOTE: The lower intake manifold must be installed within fifteen minutes of applying sealant.

Position the lower intake manifold.
1 Apply a bead of sealant to the lower intake manifold mounting at the points indicated.
2 Position the lower intake manifold.





4. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.

Install the (A) long bolts and the (B) short bolts.





5. Tighten the bolts in two stages in the sequence shown:
- Stage 1: Tighten the bolts to 5 Nm (44 inch lbs.).
- Stage 2: Tighten the bolts to 10 Nm (89 inch lbs.).
6. Connect the fuel lines.





7. Connect the fuel pressure regulator vacuum line and the IMRC electrical connector.
8. Install the upper radiator hose to the lower intake manifold.





9. Connect the EGR valve vacuum hose.





10. Install the EGR valve tube upper fitting.





11. Connect the water bypass hose and the heater water hose.





12. NOTE: Left shown, right similar.

Connect the fuel injector electrical harness to the fuel injector supply manifold.





13. NOTE: One shown, all similar.

Connect the fuel injector electrical connectors.
14. Install the intake manifold spacer assembly.