Lower Intake Manifold

Lower Intake Manifold

Material:

Removal

1. Remove the intake manifold spacer assembly.






2. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.






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






5. Disconnect the intake manifold runner control (IMRC) electrical connector.
6. Remove the fuel rail.






7. Disconnect the water bypass hose and the heated positive crankcase ventilation (PCV) system heater water hose.






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






9. Remove and discard the lower intake manifold sealing components.

Installation






1. Refer to the illustration for intake manifold sealing component locations.






2. Install the lower intake manifold front and rear end seals.
1. Apply a bead of silicone gasket and 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.






3. Install the intake manifold gaskets.

Note: The lower intake manifold must be installed within four minutes of applying sealant.






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

Note: Make sure the bolts are installed in the correct location.






5. Loosely install the (A) long bolts and the (B) short bolts.






6. Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten the bolts to 5 Nm (44 lb-in.).
- Stage 2: Tighten the bolts to 10 Nm (89 lb-in.).
7. Connect the water bypass hose and the heated PCV system heater water hose.






8. Install the fuel rail.






9. Connect the IMRC electrical connector.
10. Install the upper radiator hose to the lower intake manifold.






11. Connect the EGR valve vacuum hose.






12. Install the EGR valve to exhaust manifold tube upper fitting.