Lower

LOWER INTAKE MANIFOLD






WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.

1. Perform fuel pressure release procedure. Service and Repair
2. Remove and isolate negative battery cable at battery.
3. Drain the cooling system Service and Repair.
4. Remove the upper intake manifold including EGR tube, PCV, purge and power brake booster vacuum hoses Intake Manifold - Removal.





5. Disconnect the fuel supply hose (1) from fuel rail Service and Repair.
6. Disconnect electrical connectors (3) at all six fuel injectors. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
7. Remove four fuel rail mounting bolts (2).
8. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
9. Remove fuel rail (with injectors attached) from engine.





10. Disconnect the coolant temperature sensor (2) and knock sensor (4) electrical connectors.
11. Disconnect the coolant hose (5) from the thermostat housing.
12. Disconnect heater hose (1) from the rear of the lower intake manifold (3).





13. Remove the four remaining bolts attaching lower intake and remove intake manifold (1) and gaskets (2).