Removal and Installation of Intake Manifold - Lower Manifold

Perform this procedure only after the engine has completely cooled down.

PROCEDURE

1. Remove the power steering pump (refer to Suspension and Steering) and move it aside without disconnecting the hoses.
2. Label and disconnect the wiring from the fuel injectors. Remove the fuel lines from the lower intake manifold (refer to Fuel and Exhaust Systems).

3. Remove the mounting bolts and nuts and remove both lower intake manifold sections from the cylinder heads. If either section is stuck and does not separate, tap around its perimeter with a hammer.

Do not attempt to separate the manifold by prying between the mating surfaces. Any mechanical damage to these surfaces may lead to leaks.
The fuel injectors may be left in place.

4. Using a scraper made of a relatively soft material, carefully clean the mating surfaces of the manifold and cylinder heads of sealant residue and old gasket material. Then wipe the surfaces with a rag moistened with acetone.

5. Install new gaskets, then install the lower intake manifold sections onto the cylinder heads.

Make sure the gaskets are correctly seated on the locating pins. Install the section fasteners.
6. Tighten the fasteners to the specified torque in three stages. To prevent distortion, work from the center of the sections outward, tightening the fasteners in a diagonal sequence.
7. Install the remaining components in the reverse order of removal.
8. Check the coolant level and top up if necessary (refer to Maintenance and Adjustments).
9. Start the engine and check for fuel and coolant leaks. Also make sure there is no loss of vacuum.