Lower Intake Manifold

Lower Intake Manifold

Removal
1. Remove the upper intake manifold.
2. Disconnect the fuel hose spring lock couplings.





3. Disconnect the engine water bypass hose.





4. Disconnect the water temperature indicator sender electrical connector.





5. Disconnect the upper radiator hose, the heater water inlet hose and the heated Positive Crankcase Ventilation (PCV) water heated fitting inlet hose.





6. Remove the four bolts and the generator upper support bracket.





7. Disconnect the eight fuel injectors.





8. Disconnect the fuel injector pressure regulator vacuum hose and position out of the way.





9. Disconnect the wire harness pin-type retainer.





10. Remove the bolts and lower intake manifold.
^ Discard the bolts.





11. Remove the bolts and the radio ignition interference capacitors.





12. Remove and inspect the gaskets, and install new gaskets if necessary.





13. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the sealing surfaces.


Installation





1. Install the lower intake gaskets.





2. Install the radio ignition interference capacitors.





3. NOTE: Install new bolts.

Position the lower intake manifold. Loosely install the retaining bolts.





4. Tighten the retaining bolts in two stages, and then an additional 90° in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
^ Tighten an additional 90°.





5. Connect the wire harness pin-type retainer.





6. Connect the water temperature indicator sensor electrical connector.





7. Position the vacuum harness and connect the vacuum line to the fuel injector pressure regulator.





8. Connect the eight fuel injector electrical connectors.





9. Install the upper generator support bracket and the four bolts.





10. Connect the heater water inlet hose, the upper radiator hose and the water heated fitting inlet hose.





11. Connect the engine water bypass return hose.
12. Connect the fuel hose spring lock couplings.
13. Install the upper intake manifold.