Lower Intake Manifold Replacement

Lower Intake Manifold Replacement (L32)

Removal Procedure




1. Drain the cooling system.
2. Remove the supercharger.
3. Remove the radiator inlet hose from the water outlet housing.




4. Remove the exhaust gas recirculation (EGR) outlet pipe bolt (2) from the lower intake manifold.
5. Remove the EGR outlet pipe (1) from the lower intake manifold.
6. Disconnect the engine coolant temperature (ECT) sensor electrical connector.




7. Remove the lower intake manifold bolts.
8. Remove the lower intake manifold. The coolant bypass tube will release from the intake manifold as the manifold is removed.
9. Remove the lower intake manifold seals.
10. Remove the lower intake manifold gaskets.
11. If replacing the lower intake manifold, remove the water outlet housing and the thermostat.
12. If replacing the lower intake manifold, remove the ECT sensor.
13. Inspect the flatness of the inlet flanges.
14. Clean the lower intake manifold gasket mating surfaces.
15. Clean the intake manifold bolts and the bolt holes of the adhesive compound.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.

1. If removed, install the ECT sensor.

Tighten the ECT sensor to 25 N.m (18 lb ft).




2. If removed, install the thermostat, the gasket, and the water outlet housing.
3. Install the water outlet housing bolt and the stud.

Tighten the bolt and the stud to 27 N.m (20 lb ft).




4. Install the intake manifold gaskets.
5. Apply sealer to the ends of the intake seals.
6. Install the lower intake manifold seals.




7. Align the coolant bypass tube with the opening in the manifold. Install the lower intake manifold.
8. Install the lower intake manifold bolts.

Tighten the lower intake manifold bolts from the center to the outside in sequence to 15 N.m (11 lb ft).

9. Connect the ECT sensor electrical connector.




10. Install the EGR outlet pipe (1) to the lower intake manifold.
11. Install the EGR outlet pipe bolt (2).

Tighten the bolt to 29 N.m (21 lb ft).




12. Install the radiator inlet hose to the water outlet housing.
13. Install the supercharger.
14. Fill the cooling system.
15. Inspect for fluid or vacuum leaks.