Lower

This article has been updated by technical service bulletin (TSB) 94-10-10 dated 05/18/94.

Lower Intake Manifold Removal

1. Remove upper intake manifold as outlined.
2. Remove fuel injector and fuel injection supply manifold.
3. Remove heater water hose.
4. Remove lower intake manifold retaining bolts.

CAUTION: The lower intake manifold is sealed at each corner with RTV-type sealer. To break the seal, it may be necessary to pry on the front of the intake manifold with a screwdriver blade. If it is necessary to pry on the lower intake manifold use care to prevent damage to machined surfaces.

5. Remove lower intake manifold.






6. Remove intake manifold gasket (9439) and end seals, and discard.
7. If lower intake manifold assembly is to be disassembled, perform the following:

Note: The water bypass tube is pressed-in, and not serviceable.






a. Remove clutch pressure plate (7563) and water thermostat (8575).
b. Remove water temperature indicator sender unit (10884).
c. Remove hot water heater elbow connection.
d. Remove all vacuum and electrical fittings.

Lower Intake Manifold Installation

Note: Lightly oil all retaining bolt and stud bolt threads before installation.

Note: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced.

1. The lower intake manifold, cylinder head, and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.
2. If intake manifold was disassembled:
- Apply a coat of Pipe Sealant with Teflon� D8AZ-19554-A (WSK-M2G350-AZ and ESR-M18P7-A) or equivalent to the threads of the water temperature indicator sender unit, all vacuum fittings, hot water heater elbow connections, electrical fittings, if equipped.
- Install water thermostat (note direction) and clutch pressure plate.
Install water outlet connection.
Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).

Note: Using solvent, clean sealing surfaces of cylinder heads and intake manifold before applying Silicone Sealer.

3. Apply a dab of Gasket and Trim Adhesive D7AZ-19B508-B (M11P17-A and ESE-M2G52-A) or equivalent to each cylinder head mating surface.
Press new intake manifold gaskets into place, using locating pins as necessary to aid in assembly.
4. Apply a 3-4mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent at each corner where the cylinder head joins the cylinder block.
5. Install front and rear intake manifold end seals.
6. Carefully install intake manifold into position on cylinder block and cylinder heads.
Use locating pins as necessary to guide intake manifold.






7. Tighten in two steps in numerical sequence to the following specifications:
Step 1 18 Nm (13 ft. lbs.)
Step 2 22 Nm (16 ft. lbs.)
8. Connect rear crankcase ventilation tube.
9. Install front crankcase ventilation tube so the mounting bracket sits over the lower intake manifold stud.
10. Install fuel injectors and fuel injection supply manifold.
Tighten screws to 8-11 Nm (6-8 ft. lbs.).
11. Install upper intake manifold.