Disassembly and Assembly
Intake Manifold AssemblyDisassembly
1. Remove the fuel infection supply manifold.
2. Remove the fuel injectors from the fuel injection supply manifold.
3. Inspect the two O-ring seals from each fuel injector. Install new O-ring seals as needed.
4. Remove the engine noise shield.
5. Remove the bolts.
6. Separate the upper and lower intake manifolds and discard the lower intake manifold gasket.
7. Remove the bolts from the intake manifold turning valve and remove the valve.
8. CAUTION: If the engine has been internally damaged and metal or other foreign material has entered the manifold, it is recommended the manifold be discarded.
Inspect all external and internal surfaces of the upper intake manifold.
^ Inspect for cracks or other damage.
^ Inspect for foreign material inside of the manifold.
^ Clean the upper intake manifold with metal surface cleaner.
9. CAUTION: If the engine has been internally damaged and metal or other foreign material has entered the manifold, it is recommended the manifold be discarded.
Inspect all external and internal surfaces of the lower intake manifold.
^ Inspect for cracks or other damage.
^ Inspect for foreign material inside of the manifold.
^ Clean the lower intake manifold with metal surface cleaner.
10. Allow the upper and lower intake manifolds to dry completely.
Assembly
1. Position the intake manifold taming valve and install the bolts.
2. Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.
3. Tighten the bolts in two stages using the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).
4. Install the engine noise shield.
5. NOTE: Lubricate the O-ring seals with clean engine oil, to aid installation.
Install the fuel rejectors into the fuel injection supply manifold.
6. Install the fuel injection supply manifold.