Lower

Lower Intake Manifold

Removal
1. Remove the upper intake manifold.
2. Partially drain the cooling system.
3. Relieve the fuel system pressure.





4. Disconnect the fuel rail pressure (FRP) sensor electrical connector and vacuum hose.
5. Disconnect the fuel supply tube spring lock coupling.





6. Disconnect and position the engine wire harness aside.





7. Disconnect the intake manifold runner control (IMRC) electrical connector.
8. Remove the heater bypass tube.





9. Disconnect the heater hose.





10. Disconnect the exhaust gas recirculation (EGR) vacuum tube.





11. Disconnect the EGR tube from the EGR valve.





12. Disconnect the radiator upper hose and coolant bypass hose.





13. Disconnect the electrical connector.





14. NOTE: Remove the fuel injection supply manifold and fuel injectors as an assembly.

Remove the bolts and the fuel injection supply manifold.





15. NOTE: For ease in installation, record the location of the short bolts and the long bolts.

Remove the lower intake manifold.
1. Remove the eight short bolts.
2. Remove the six long bolts.
3. Remove the lower intake manifold.





16. Remove and discard the intake manifold gaskets.

Installation





1. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Install the lower intake manifold front and rear end seals.
1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated.
2. Install the lower intake manifold front and rear end seals.





2. Install the intake manifold gaskets.





3. NOTE: If the lower intake manifold is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Position the lower intake manifold.
1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated.
2. Position the lower intake manifold.





4. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.

Tighten the bolts in two stages in the sequence shown:
- Stage 1: Tighten the bolts to 5 Nm (44 inch lbs.).
- Stage 2: Tighten the bolts to 10 Nm (89 inch lbs.).





5. NOTE: Install the fuel injection supply manifold and fuel injectors as an assembly.

Install the fuel injector supply manifold and bolts.





6. Connect the electrical connector.





7. Connect the coolant hoses.





8. Connect the EGR tube.





9. Connect the EGR vacuum tube.





10. Lubricate the O-ring with water and install the heater hose.
11. Install the heater bypass tube.





12. Connect the IMRC electrical connector.





13. Position and connect the engine wire harness. Install the pin-type retainers.
14. Connect the fuel supply tube spring lock coupling.





15. Connect the FRP sensor electrical connector and the vacuum hose.
16. Install the upper intake manifold.

17. CAUTION: Correct cooling system bleeding is critical for correct engine cooling.

Fill and bleed the cooling system.