Lower Intake Manifold

Lower Intake Manifold





Material

Removal
1. Drain the engine cooling system.
2. Disconnect the fuel tube spring lock coupling.
3. Remove the upper intake manifold.
4. Remove the LH and the RH valve covers.





5. Disconnect the Fuel Rail Pressure (FRP) sensor electrical and vacuum connections.





6. Disconnect the fuel injector electrical connectors.





7. Remove the fuel injection supply manifold and fuel injectors as an assembly.





8. Disconnect the heater hose and Engine Coolant Temperature (ECT) sender electrical connector.





9. Disconnect the ECT sensor electrical connector and the degas bottle hose.





10. Disconnect the upper radiator hose from the thermostat housing.
11. Remove the Camshaft Position (CMP) sensor.




12. Remove the bolts and the lower intake manifold.





13. Remove the intake manifold gaskets and the end seals.

Installation





1. Using metal surface cleaner, clean all the sealing surfaces.





2. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the four cylinder block-to-cylinder head seams.





3. Install the lower intake manifold gaskets and end seals.
^ Position the intake manifold gaskets.
^ Position the intake manifold end seals.





4. Install the intake manifold. Tighten the bolts in two stages in the sequence shown.
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 32 Nm (24 ft. lbs.).

5. Install the Camshaft Position (CMP) sensor.





6. Connect the upper radiator hose to the thermostat housing.





7. Connect the Engine Coolant Temperature (ECT) sensor electrical connector and the degas bottle hose.





8. Connect the heater hose and the ECT sender electrical connector.





9. Install the fuel injection supply manifold and fuel injectors as an assembly.





10. Connect the fuel injector electrical connectors.





11. Connect the Fuel Rail Pressure (FRP) sensor electrical and vacuum connections.
12. Install both valve covers.
13. Install the upper intake manifold.
14. Connect the fuel tube spring lock coupling.
15. Fill and bleed the engine cooling system.