Lower Intake Manifold Replacement

Lower Intake Manifold Replacement

Removal Procedure

1. Drain the cooling system.
2. Remove the upper intake manifold.
3. Remove the heater inlet pipe.
4. Disconnect the radiator inlet hose from the thermostat housing.
5. Remove the fuel rail assembly.




6. Remove the lower intake manifold bolts.
7. Remove the lower intake manifold from the engine.
8. If replacing the lower intake manifold, remove the thermostat and housing.
9. Remove the rocker arms and push rods.




10. Remove the lower intake manifold gaskets.

Installation Procedure





Important: All gasket mating surfaces must remain free of oil and foreign material. Refer to Sealers, Adhesives, and Lubricants for the correct part number to use to clean surfaces.

Important: Do not apply room temperature vulcanizing (RTV) sealer to the engine block prior to the installation of the manifold gaskets. RTV sealer is not to be placed under the lower intake manifold gaskets.

1. Install the lower intake manifold gaskets.
2. Install the rocker arms and push rods.




3. Install the lower intake manifold seals.
4. With the seals in place, apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer.
5. Install the lower intake manifold to the engine.





Notice: Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

Notice: Refer to Fastener Notice.

Important: All lower intake manifold bolts need to be clean, free of foreign materials, and reused only if new bolts are unavailable. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Apply to the old intake manifold bolt threads.

Important: Manufacturer recommends the center bolts be fully torqued before the diagonal bolts to assure proper torque distribution.

Important: Lower intake manifold bolts in locations (6) and (7) should be torqued to specification using a crows foot type tool.

6. Install the lower intake manifold bolts.

1. Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the first pass.
2. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft) on the final pass.
3. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.

7. Install the fuel rail assembly.
8. Connect the radiator inlet hose to the thermostat housing.
9. Install the heater inlet pipe.
10. Install the upper intake manifold.
11. Fill the cooling system.