Lower Intake Manifold

1. Disconnect the negative battery cable.
2. Drain the engine cooling system.
3. Remove both valve covers.




4. Disconnect the radio ignition interference capacitor, ignition coil and EGR solenoid connections.




5. Remove the ignition coil and plug wires as an assembly.




6. Disconnect the crankshaft position sensor (CKP) sensor, engine coolant temperature (ECT) sensor, water temperature indicator sender unit, fuel injectors and camshaft synchronizer connections.
7. Relieve the fuel pressure and disconnect the fuel line. See PUSH CONNECT FITTINGS.




8. Remove the fuel rail and the fuel injector as an assembly.




9. Disconnect the heater hoses.
10. Disconnect the upper radiator hose.




11. Disconnect the coolant bypass tube.




12. Remove the heater hose connection.

NOTE: Identify the location of each rocker arm. Each rocker arm is to be installed in the original location to prevent premature wear.




13. Remove the rocker arms.

NOTE: Identify the location of each push rod. Each push rod is to be installed in the original location to prevent premature wear.

14. Remove the push rods.




15. Remove the bolts.




16. Remove the lower intake manifold.




17. Remove the intake manifold gaskets and end seals.
18. Install in reverse order of removal.

Lower Intake Manifold Gasket Installation Note
1. Clean all the sealing surfaces.




2. Install the intake manifold gaskets and seals.
1. Apply a drop of silicone sealant at the four cylinder block-to-cylinder head seams.
2. Position the intake manifold gaskets.
3. Position the intake manifold front and rear seals.

Lower Intake Manifold Bolt Installation Note




1. Install the bolts and tighten in the sequence shown.