Lower Intake Manifold Replacement

Lower Intake Manifold Replacement

Removal Procedure





Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

1. Remove the upper intake manifold.
2. Remove the generator brace.
3. Remove the drive belt tensioner with the heater water bypass inlet pipe.




4. Remove the exhaust gas recirculation (EGR) outlet pipe bolt (2) from the lower intake manifold.
5. Remove the EGR outlet pipe (1) from the lower intake manifold.




6. Remove the radiator inlet hose from the water outlet housing.




7. Disconnect the engine coolant temperature (ECT) sensor electrical connector.




8. Remove the generator brace bracket bolts.
9. Remove the generator brace bracket.




10. Remove the lower intake manifold bolts.
11. Remove the lower intake manifold.




12. Remove the lower intake manifold seals.




13. Remove the lower intake manifold gaskets.




14. If replacing the lower intake manifold, remove the water outlet housing bolt, stud and the water outlet housing.
15. If replacing the lower intake manifold, remove the ECT sensor.
16. Inspect the flatness of the inlet flanges.
17. Clean the intake manifold gasket mating surfaces.
18. Clean the intake manifold bolts and bolt holes of adhesive compound.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.

1. If removed, install the ECT sensor.

Tighten the sensor to 25 N.m (18 lb ft).




2. If removed, install the thermostat, the gasket, and the water outlet housing.
3. Install the water outlet housing bolt and the stud.

Tighten the bolt and the stud to 27 N.m (20 lb ft).




4. Install the lower intake manifold gaskets.




5. Apply sealer to the ends of the intake manifold seals.
6. Install the lower intake manifold seals.





Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

7. Install the lower intake manifold.
8. Apply threadlock compound to the two hidden bolts.




9. Install the lower intake manifold bolts (1-12).

Tighten the lower intake manifold bolts in sequence to 15 N.m (11 lb ft).




10. Install the generator brace bracket.
11. Install the generator brace bracket bolts.

Tighten the bolts to 50 N.m (37 lb ft).




12. Connect the ECT sensor electrical connector.




13. Install the radiator inlet hose to the water outlet housing.




14. Install the EGR outlet pipe (1) to the lower intake manifold.
15. Install the EGR outlet pipe bolt (2) to the lower intake manifold.

Tighten the bolt to 29 N.m (21 lb ft).




16. Install the drive belt tensioner.
17. Install the generator brace.
18. Install the upper intake manifold.
19. Inspect for fluid or vacuum leaks.