Intake Manifold Lower Removal/Installation

INTAKE MANIFOLD LOWER REMOVAL/INSTALLATION

Removal

1. Drain the engine cooling system. See ENGINE COOLANT REPLACEMENT.
2. Remove both valve covers. See VALVE COVER - RH REMOVAL/INSTALLATION, VALVE COVER - REMOVAL/INSTALLATION.




3. Disconnect the following electrical connectors:
1. Crankshaft position (CKP) sensor.
2. Engine coolant temperature (ECT) sensor.
3. Water temperature indicator sender.
4. Fuel injectors.
5. Camshaft position (CMP) sensor.

4. Relieve the fuel system pressure and disconnect the fuel line. See FUEL LINE AND VAPOR LINE QUICK DISCONNECT FITTINGS.




5. Remove the fuel injection supply manifold and the fuel injectors as an assembly.

6. Disconnect the upper radiator hose.




7. Disconnect the bypass hose.




8. Loosen the bolt for the rocker arm at the number three cylinder intake valve.
9. Remove the push rod for the number three cylinder intake valve.




10. Remove the bolts from the lower intake manifold.

NOTE: Gently loosen the intake manifold to separate the silicone sealant from the cylinder block.




11. Remove the lower intake manifold.




12. Remove and discard the intake manifold gaskets and end seals.

Installation




1. Clean all sealing surfaces.

NOTE: If the lower intake manifold is not installed within four minutes, remove the sealant and reapply.




2. Install the intake manifold gaskets and seals.
1. Apply a drop of silicone gasket and 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.




3. Position the lower intake manifold.




4. Install the lower intake manifold bolts and tighten in the sequence shown.
5. Install the push rod for the number three cylinder intake valve.




6. Tighten the rocker arm.




7. Connect the bypass hose.
8. Connect the upper radiator hose.




9. Install the fuel injection supply manifold and the fuel injectors as an assembly.
10. Connect the fuel line. See FUEL LINE AND VAPOR LINE QUICK DISCONNECT FITTINGS.




11. Connect the following electrical connectors:
1. Crankshaft position (CKP) sensor.
2. Engine coolant temperature (ECT) sensor.
3. Water temperature indicator sender.
4. Fuel injectors.
5. Camshaft position (CMP) sensor.

12. Install both valve covers. See VALVE COVER - RH REMOVAL/INSTALLATION - 4.0L, VALVE COVER - LH REMOVAL/INSTALLATION - 4.0L.
13. Fill and bleed the engine cooling system. See ENGINE COOLANT REPLACEMENT - 2.3L.