Intake Manifold Assembly - Disassembly and Assembly

Intake Manifold Assembly













Disassembly

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. NOTE: When removing the fuel rail, leave the fuel injectors in the intake manifold. This will make removal of the fuel rail easier.

Remove the 4 fuel rail bolts.

2. Separate the fuel rail from the 8 fuel injectors and remove the fuel rail.

3. Remove the 8 fuel injectors from the intake manifold.
- Remove and discard the fuel injector O-ring seals.

4. Remove the 6 engine coolant crossover assembly bolts.

5. Remove the engine coolant crossover assembly.
- Discard the gaskets.

Assembly

1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Position new engine coolant crossover assembly gaskets, the engine coolant crossover assembly and install the 6 bolts.

- Tighten to 10 Nm (89 lb-in).

2. NOTE: Install new fuel injector O-ring seals on the fuel injectors.

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

Using new O-ring seals, install the fuel injectors into the intake manifold.

3. Install the fuel rail and the 4 fuel rail bolts.
- Tighten to 10 Nm (89 lb-in).