Lower Intake Manifold

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: It is not necessary to remove the fuel rail from the intake manifold assembly.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Release the fuel system pressure. For additional information, refer to Section 310-00 .

3. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

4. Drain the cooling system. For additional information, refer to Section 303-03 .

5. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in this section.

6. Disconnect the 6 fuel injector electrical connectors.

7. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in Section 310-00 .
   • Remove the fuel supply tube-to-engine front cover bolt.

8. Remove the 2 thermostat housing-to-lower intake manifold bolts.

9. Remove the 10 bolts and the lower intake manifold.
   • Remove and discard the intake manifold and thermostat housing gaskets.
   • Clean and inspect all sealing surfaces.

Installation

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

   Using new lower intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts.
   • Tighten in the sequence shown to 10 Nm (89 lb-in).

2. Install the 2 thermostat housing-to-lower intake manifold bolts.
   • Tighten to 10 Nm (89 lb-in).

3. Connect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in Section 310-00 .
   • Install the fuel supply tube-to-engine front cover bolt and tighten to 10 Nm (89 lb-in).

4. Connect the 6 fuel injector electrical connectors.

5. Install the upper intake manifold. For additional information, refer to Upper Intake Manifold in this section.

6. Connect the battery ground cable. For additional information, refer to Section 414-01 .

7. Fill and bleed the cooling system. For additional information, refer to Section 303-03 .