Lower Intake Manifold

LOWER INTAKE MANIFOLD

NOTE: Turbo charged engines could be equipped with either an aluminum or a plastic manifold.





1. Clean all gasket surfaces.
2. Naturally Aspirated Engine: Position new seals on lower intake manifold.
3. Turbocharged Engine: Replace lower intake manifold gasket.




4. Naturally Aspirated Engine: Install lower intake manifold. Tighten fasteners to 12 Nm (105 in. lbs.) in sequence shown in.
5. Turbocharged Engine: Install lower intake manifold. If equipped with an aluminum manifold, tighten fasteners to 28 Nm (250 in. lbs.) in sequence shown. If equipped with a plastic manifold, tighten fasteners to 12 Nm (105 in. lbs.) in sequence shown.




6. Turbocharger Equipped Engine: Install fasteners for lower intake manifold support bracket (3). If equipped with an aluminum manifold, torque fasteners to 54 Nm (40 ft. lbs.). If equipped with a plastic manifold, torque manifold fasteners to 6 Nm (55 in. lbs.).




7. If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 Nm (200 in. lbs.).
8. Connect fuel injector wiring harness.
9. Inspect quick connect fittings for damage, replace if necessary Service and Repair. Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.




10. Install the screw attaching the oil dipstick tube to lower intake manifold.




11. Install thermostat (3) and coolant outlet connector (2).




12. Install radiator upper hose (1).
13. Install upper intake manifoldIntake Manifold - Installation.




14. Connect negative cable to battery (1).
15. Fill the cooling system.
16. With the DRBIII(R) scan tool use ASD Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.

17. Start engine and check for leaks.