Lower Intake Manifold

Lower Intake Manifold

Removal
1. Drain the engine cooling system.
2. Remove the upper intake manifold.
3. Disconnect the fuel line spring lock coupling.





4. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connectors.





5. Disconnect the coolant hoses.





6. Disconnect the coolant hoses, the electrical connectors, and the wiring harness retainer.
7. Remove the accessory drive belt.





8. Remove the bolts and the generator support bracket.





9. Remove the crossover tube.





10. Remove the bolts and the generator.





11. Disconnect the electrical connector and the vacuum hose from the fuel pressure sensor.





12. Separate the wiring harness from the fuel injection supply manifold studs in four places.





13. Disconnect the eight fuel injector electrical connectors.





14. Remove the ten bolts in the sequence shown, and raise the lower intake manifold slightly.
15. Disconnect the fuel charging wiring harness from the rear of the lower intake manifold.
^ Remove the manifold.





16. Remove the intake manifold gaskets.
^ Clean and inspect the sealing surfaces.

Installation





1. Install the lower intake manifold gaskets.
^ Inspect the gaskets, install new gaskets if necessary.





2. Install the intake manifold fasteners and tighten in the sequence shown.
3. Connect the fuel charging wiring harness to the rear of the lower intake manifold.
^ Install the manifold.





4. Connect the eight fuel injector electrical connectors.





5. Position the fuel charging wiring and connect to the fuel injection supply manifold in four places.





6. Connect the electrical connector and the vacuum hose to the fuel pressure sensor.





7. Install the generator and the bolts.





8. Install the crossover tube pipe.
^ Inspect and install new O-ring seals if necessary.





9. Install the generator support bracket and the four bolts.
10. Install the accessory drive belt.





11. Connect the coolant hoses, electrical connectors, and the wiring harness retainer.





12. Connect the Engine Coolant Temperature (ECT) sensor electrical connectors.





13. Connect the coolant hoses.
14. Connect the fuel hose spring lock coupling.
15. Install the upper intake manifold.
16. Fill and bleed the engine cooling system.