Intake Manifold Assembly

Intake Manifold Assembly





Material

Disassembly





1. Disconnect the heated positive crankcase valve (PCV) coolant hose.





2. Remove the (A) coolant thermostat and the (B) O-ring seal.
^ Discard the (B) O-ring seal.





3. Remove the Throttle Body (TB) adapter.
^ Remove the four bolts.
^ Remove the TB adapter.
^ Discard the TB adapter press-in-place gasket.





4. Remove the five bolts holding the fuel injection supply manifold assembly and the fuel injectors.
^ Discard the fuel injector O-ring seals.





5. Separate the upper and lower intake manifolds.
^ Remove the bolts.
^ Discard the intake manifold gasket.

6. Using clean metal surface cleaner, clean and inspect the upper and lower manifold internal passages and mating surfaces.
7. Allow the upper and lower intake manifolds to dry completely.

Assembly





1. Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.





2. Tighten the bolts in two stages using the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).





3. CAUTION: Check for leakage after installation is complete.

NOTE: Be sure fuel injectors and fuel rail are fully seated.

Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation. Install the fuel rail.





4. Install the TB adapter.
^ Position a new TB adapter press-in-place gasket.
^ Position the TB adapter.
^ Install the four bolts in 2 stages:
- Stage 1: Tighten to 9 Nm (80 inch lbs.).
- Stage 2: Tighten an additional 90 degrees.





5. NOTE: The thermostat must be installed as illustrated.

Use a new (A) O-ring seal to position the (B) coolant thermostat in the (c) upper intake manifold.





6. Connect the heated PCV hose.