Lower Intake Manifold

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

REMOVAL
1. Perform fuel pressure release.
2. Drain cooling system. Refer to Cooling System for procedure.
3. Remove upper intake manifold.
4. Disconnect electrical connectors to fuel injectors and coolant temperature sensor.





Fig. 54

5. Disconnect heater and coolant bottle supply hoses from coolant tube at rear of intake manifold (Fig. 54).
6. Disconnect fuel supply hose from fuel rail.
7. Remove screw attaching fuel rail support bracket to the throttle body support bracket.
8. Remove bolts attaching fuel rail.
9. Remove fuel rail and injectors as an assembly.





Fig. 55

10. Remove bolts attaching lower intake and remove intake manifold (Fig. 55).

INSTALLATION
1. Clean all sealing surfaces.

NOTE: Gaskets can be reused provided they art free of tears or cuts.

2. Inspect gaskets for tears or cuts. Replace all that are necessary.
3. Position gaskets and intake manifold on cylinder head surfaces.
4. Install fuel rail with injectors.





Fig. 56

5. Install intake manifold bolts and gradually tighten in sequence shown in (Fig. 56) until a torque of 28 Nm (250 in. lbs.) is obtained.
6. Install screw attaching fuel rail support bracket to the throttle body support bracket.
7. Connect fuel supply hose to fuel rail.
8. Connect heater and coolant bottle supply hoses to coolant tube at rear of intake manifold (Fig. 54).
9. Connect electrical connectors to fuel injectors and coolant temperature sensor.
10. Install upper intake manifold.
11. Fill cooling system.
12. With the DRBIII scan tool use ASD Fuel System Test to pressurize fuel system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.