Lower

REMOVAL

1. Disconnect battery ground cable, then drain cooling system.
2. Disconnect electrical connectors from knock sensor, fan temperature sensor, fuel injection wiring harness and instrument cluster coolant temperature sender.
3. Disconnect coolant bypass line from lower intake manifold.
4. Depressurize EFI fuel system using a hand operated vacuum pump. Connect pump hose at fuel system pressure regulator and apply at least 25 inches vacuum. Fuel supply lines will remain pressurized for some period of time after engine is shut off. System pressure must be relieved before disconnecting any fuel lines.
5. Disconnect vacuum pump from fuel pressure regulator.
6. Disconnect fuel supply line from fuel supply manifold.
7. Disconnect fuel return line using tool No. T82L-950-AH or equivalent.
8. Remove nut attaching pulse damper to bracket and position pulse damper and fuel supply line out of way.
9. Remove upper intake manifold as previously described.
10. Disconnect EEC coolant temperature sensor.
11. Remove four upper and four lower attaching bolts and the lower intake manifold and gasket.
12. Remove two attaching bolts, disengage each injector and remove fuel supply manifold assembly.

Fig. 11 Lower Intake Manifold Bolt Tightening Sequence:

INSTALLATION

1. Clean and inspect mounting surfaces of lower intake manifold and the cylinder head, ensuring that both surfaces are clean and flat.
2. Install new gasket.
3. Position lower intake manifold on cylinder head and install four upper attaching bolts finger tight.
4. Install four lower manifold bolts and torque to specifications, in proper sequence, Fig. 11.
5. Install fuel supply manifold assembly by pressing each injector into place on lower intake manifold and installing two attaching bolts.
6. Ensure that gasket surfaces of upper and lower intake manifolds are clean.
7. Install EEC coolant temperature sensor.
8. Install upper intake manifold and two gaskets.
9. Connect fuel return line.
10. Place pulse damper on bracket and connect fuel supply line.
11. Connect coolant bypass line to lower intake manifold.
12. Connect electrical connectors at knock sensor, fan temperature sensor, fuel injection wiring harness and the instrument cluster coolant temperature sender.
13. Connect battery ground cable and refill cooling system.