Intake Manifold Replacement (Lower)

REMOVAL PROCEDURE





1. Disconnect the battery negative cable from the battery.

IMPORTANT: Do not attempt to remove the upper and lower intake manifold as an assembly from the engine. Damage to the upper and lower intake manifolds as well as the turbocharger could occur upon reinstallation of these components.

2. Remove the upper intake manifold from the lower intake manifold.
3. Remove the boost sensor relay.
4. Remove the glow plug relay.
5. Mark the following components in order to ensure proper reinstallation:
^ The fuel line retaining clips
^ The lower intake manifold studs.
^ The electrical harness retaining clips and ground straps.

6. Remove the lower intake manifold studs and fuel line clips.
7. Remove the lower intake manifold and gaskets from the cylinder heads.

INSTALLATION PROCEDURE





1. Install the lower intake manifold gasket to the cylinder head.
2. Install the lower intake manifold bolts to the cylinder head.
^ Tighten the bolts to 42 Nm (31 ft. lbs.).

NOTICE: Refer to Fastener Notice Service Precautions.

3. Install the fuel line retaining clips.
4. Install the electrical harness retaining clips and ground straps.
5. Install the glow plug relay to the lower intake manifold.
6. Install the boost sensor relay to the lower intake manifold.
7. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement (Upper)
8. Connect the battery negative cables to the batteries.