Intake Manifold Replacement (Lower Intake Manifold)

Intake Manifold Replacement (Lower Intake Manifold)

Removal Procedure

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.
2. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling in Engine Cooling.




3. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement (Upper Intake Manifold) Intake Manifold Replacement (Upper Intake Manifold)Intake Manifold Replacement (Lower Intake Manifold) .
4. Remove the MAP sensor from the lower intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement Service and Repair in Engine Controls.
5. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement in Engine Cooling.
6. Remove the thermostat housing from the lower intake manifold. Refer to Engine Coolant Thermostat Housing Replacement Service and Repair in engine cooling.
7. Remove the heater hoses from the heater core. Refer to Heater Hoses Replacement (LP4/L21 Inlet) Heater Hoses Replacement (LP4/L21 Inlet)Heater Hoses Replacement (LP4/L21 Outlet) Heater Hoses Replacement (LP4/L21 Outlet)Heater Hoses Replacement (LG5 Inlet) Heater Hoses Replacement (LG5 Inlet)Heater Hoses Replacement (LG5 Outlet) Heater Hoses Replacement (LG5 Outlet) in Engine Cooling.
8. Remove the coolant bypass hose from the lower intake manifold and the water pump.
9. Remove the retaining bolts for the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair.
10. Remove the fuel rail from the lower intake manifold.




11. Remove the lower intake manifold bolts from the engine head.
12. Remove the lower intake manifold from the cylinder head.
13. Remove the lower intake manifold gaskets and seals from the cylinder head.
14. Clean all sealing surfaces of oil and grease. Refer to Intake Manifold Cleaning and Inspection (Upper) 56. Intake Manifold Cleaning and Inspection - UpperIntake Manifold Cleaning and Inspection (Lower) 57. Intake Manifold Cleaning and Inspection - Lower.

Installation Procedure




1. Install the lower intake manifold gaskets to the cylinder head with THIS SIDE UP stamped facing up.
2. Install the lower intake manifold to the engine block.
3. Apply the Loctite 242 G M P/N 12345382 to the lower intake manifold bolts.

Notice: Refer to Fastener Notice in Cautions and Notices.

4. Install the lower intake manifold bolts to the engine head.

Tighten the bolts in sequence to 30 Nm (22 lb ft).
Re-tighten the bolts in sequence to 40 Nm (30 lb ft).
5. Install the MAP sensor to the lower intake manifold. Refer to Manifold Absolute Pressure Sensor Replacement Service and Repair in Engine Controls.

Diagram:

6. Install the fuel rail to the lower intake manifold. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair in Engine Controls.
7. Install the thermostat housing to the lower intake manifold. Refer to Engine Coolant Thermostat Housing Replacement Service and Repair in Engine Cooling.
8. Install the coolant bypass hose to the water pump and intake.
9. Install the heater hoses to the lower intake manifold. Refer to Heater Hoses Replacement (LP4/L21 Inlet) Heater Hoses Replacement (LP4/L21 Inlet)Heater Hoses Replacement (LP4/L21 Outlet) Heater Hoses Replacement (LP4/L21 Outlet)Heater Hoses Replacement (LG5 Inlet) Heater Hoses Replacement (LG5 Inlet)Heater Hoses Replacement (LG5 Outlet) Heater Hoses Replacement (LG5 Outlet) in Engine Cooling.
10. Install the radiator outlet hose to the lower intake manifold. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement in Engine Cooling.




11. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement (Upper Intake Manifold) Intake Manifold Replacement (Upper Intake Manifold)Intake Manifold Replacement (Lower Intake Manifold) .
12. Refill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling in Engine Cooling.
13. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.