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    1959 Chevrolet Corvette 4.6L FI OHV 8cyl

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    Ford Ranger/Explorer/Mountaineer 1991-1999

    Intake Manifold

    Print

    The engines covered by this information utilize an upper and lower intake manifold assembly. If necessary, only the upper intake manifold may be removed by following the intake manifold procedure up to that point. Obviously, installation would also begin at the upper intake steps.

    REMOVAL & INSTALLATION




    WARNING
    Anytime the upper or lower intake manifold has been removed, cover all openings with a rag or a sheet of plastic to prevent dirt and debris from falling into the engine.

    2.3L and 2.5L Engines

    See Figures 1 through 8



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the upper and lower intake manifold assemblies on the 2.3L and 2.5L engine

    The intake manifold is a two-piece (upper and lower) aluminum casting. Runner lengths are tuned to optimize engine torque and power output. The manifold provides mounting flanges for the air throttle body assembly, fuel supply manifold, accelerator control bracket and the EGR valve and supply tube. A vacuum fitting is installed to provide vacuum to various engine accessories. Pockets for the fuel injectors are machined to prevent both air and fuel leakage. The following procedure is for the removal of the intake manifold with the fuel charging assembly attached.

    1. Make sure the ignition is off, then drain the coolant from the radiator (engine cold).
    2.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

    1. Disconnect the negative battery cable and secure it out of the way.
    2.  
    3. Remove the fuel filler cap to vent tank pressure. Release the pressure from the fuel system at the fuel pressure relief valve using EFI pressure gauge T80L-9974-A or equivalent. The fuel pressure relief valve is located on the fuel line in the upper right hand corner of the engine compartment. Remove the valve cap to gain access to the valve.
    4.  
    5. Label and unplug any electrical connectors related to the intake manifold assemblies being removed.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 2: Linkage and hose location on the 2.3L and 2.5L engine



    Click image to see an enlarged view

    Fig. Fig. 3: Disconnect the EGR valve supply tube

    1. Tag and disconnect the vacuum lines at the upper intake manifold vacuum tree, at the EGR valve and at the fuel pressure regulator and canister purge line as necessary.
    2.  
    3. Remove the throttle linkage shield and disconnect the throttle linkage and speed control cable (if equipped). Unbolt the accelerator cable from the bracket and position the cable out of the way.
    4.  
    5. Disconnect the air intake hose, air bypass hose and crankcase vent hose.
    6.  
    7. Disconnect the PCV hose from the fitting on the underside of the upper intake manifold.
    8.  
    9. Loosen the clamp on the coolant bypass line at the lower intake manifold and disconnect the hose.
    10.  
    11. Disconnect the EGR tube from the EGR valve by removing the flange nut.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 4: Upper intake manifold removal on the 2.3L and 2.5L engine

    1. Remove the upper intake manifold retaining nuts. Remove the upper intake manifold and throttle body assembly.
    2.  

    If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the procedure to also remove the lower intake manifold.



    Click image to see an enlarged view

    Fig. Fig. 5: Fuel supply manifold and connections on the 2.3L and 2.5L engine. The injectors do not need to be removed unless a new manifold is being installed



    Click image to see an enlarged view

    Fig. Fig. 6: Lower intake manifold removal on the 2.3L and 2.5L engine

    1. Disengage the push connect fitting at the fuel supply manifold and fuel return lines. Disconnect the fuel return line from the fuel supply manifold.
    2.  
    3. Remove the engine oil dipstick bracket retaining bolt.
    4.  
    5. Unplug the electrical connectors from all four fuel injectors and move the harness aside.
    6.  
    7. Remove the four bottom retaining bolts from the lower manifold. The front two bolts also secure an engine lifting bracket. Once the bolts are removed, remove the lower intake manifold.
    8.  
    9. Clean and inspect the mounting faces of the lower intake manifold and cylinder head. Both surfaces must be clean and flat. If the intake manifold upper or lower section is being replaced, it will be necessary to transfer components from the old to the new part.
    10.  

    To install:
    1. To install, first clean and oil the manifold bolt threads. Install a new lower manifold gasket.
    2.  
    3. Position the lower manifold assembly to the head and install the engine lifting bracket. Install the four top manifold retaining bolts finger-tight. Install the four remaining manifold bolts and tighten to 12-15 ft. lbs. (single plug 2.3L engines) or 15-3 ft. lbs. (2.3L and 2.5L twin plug engines), following the sequence illustrated.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 7: Lower intake manifold torque sequence on the 2.3L and 2.5L engine



    Click image to see an enlarged view

    Fig. Fig. 8: Upper intake manifold torque sequence on the 2.3L and 2.5L engine

    1. Engage the four electrical connectors to the injectors.
    2.  
    3. Install the engine oil dipstick, then connect the fuel return and supply lines to the fuel supply manifold.
    4.  

    The following procedures are for installing the upper intake manifold.

    1. Make sure the gasket surfaces of the upper and lower intake manifolds are clean. Place a gasket on the lower intake manifold assembly, then place the upper intake manifold in position.
    2.  
    3. Install the retaining bolts and tighten in sequence to 15-3 ft. lbs.
    4.  
    5. Connect the EGR tube to the EGR valve and tighten it to 18 ft. lbs.
    6.  
    7. Connect the coolant bypass line and tighten the clamp. Connect the PCV system hose to the fitting on the underside of the upper intake manifold.
    8.  
    9. If removed, install the vacuum tee on the upper intake manifold. Use Teflon® tape on the threads and tighten to 12-18 ft. lbs. Reconnect the vacuum lines to the tee, the EGR valve and the fuel pressure regulator and canister purge line as necessary.
    10.  
    11. Hold the accelerator cable bracket in position on the upper intake manifold and install the retaining bolt. Tighten the bolt to 10-15 ft. lbs.
    12.  
    13. Install the accelerator cable to the bracket.
    14.  
    15. Position a new gasket on the fuel charging assembly air throttle body mounting flange. Install the air throttle body to the fuel charging assembly. Install two retaining nuts and two bolts and tighten to 15-6 ft. lbs.
    16.  
    17. Connect the accelerator and speed control cable (if equipped), then install the throttle linkage shield.
    18.  
    19. Reconnect any electrical harness plugs which were removed.
    20.  
    21. Connect the air intake hose, air bypass hose and crankcase ventilation hose.
    22.  
    23. Reconnect the negative battery cable. Refill the cooling system to specifications and pressurize the fuel system by turning the ignition switch on and off (without starting the engine) at least six times. Leaving the ignition on for at least five seconds each time.
    24.  
    25. Start the engine and let it idle while checking for fuel, coolant and vacuum leaks. Correct as necessary. Road test the vehicle for proper operation.
    26.  

    2.9L Engine

    See Figure 9

    1. Disconnect battery negative cable.
    2.  
    3. Remove air cleaner air intake duct from throttle body.
    4.  
    5. Disconnect throttle cable and bracket assembly.
    6.  
    7. Disconnect EGR tube at EGR valve.
    8.  
    9. Label and disconnect all vacuum hoses from fittings on upper intake manifold.
    10.  
    11. Detach the electrical connections at throttle body, EGR pressure sensor, intake manifold upper and lower and distributor. Also disconnect fuel injector subharness from main EEC harness.
    12.  
    13. Remove upper intake manifold (plenum) assembly.
    14.  

    If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the procedure to also remove the lower intake manifold.

    1. Drain coolant. Remove the upper radiator and heater supply hoses from intake manifold.
    2.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

    1. Remove distributor cap and spark plug wires as an assembly.
    2.  
    3. Observe and mark the location of the distributor rotor and housing so ignition timing can be maintained at reassembly. Remove distributor hold-down screw and clamp and lift out distributor.
    4.  
    5. Remove rocker arm covers.
    6.  
    7. Remove intake manifold attaching bolts and nuts. Note length of manifold attaching bolts during removal so that they may be installed in their original positions. Tap manifold lightly with a plastic mallet to break gasket seal. Lift off manifold.
    8.  
    9. Remove all old gasket material and sealing compound.
    10.  

    To install:
    1. Apply sealing compound to the joining surfaces. Place the intake manifold gasket in position. Ensure the tab on the right hand bank cylinder head gasket fits into the cutout of the manifold gasket.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 9: Intake manifold tightening sequence and procedure for the 2.9L engine

    1. Apply sealing compound to the attaching bolt bosses on the intake manifold and position the intake manifold. Follow the tightening sequence and tighten the bolts to specifications.
    2.  
    3. Install distributor so that rotor and housing are in the same position marked at removal.
    4.  
    5. Install distributor clamp and attaching bolts.
    6.  
    7. Replace rocker arm cover gasket, and install rocker arm valve covers using the procedure under Rocker Arm Cover and Rocker Arm.
    8.  
    9. Install distributor cap. Coat the inside of each spark plug wire connector with silicone grease with a small screwdriver, and install the wires. Connect distributor wiring harness.
    10.  

    The following procedures are for installing the upper intake manifold.

    1. Apply sealing compound to the joining surfaces of the upper and lower intake manifolds. Install the upper intake manifold gaskets.
    2.  
    3. Install upper intake manifold (plenum) assembly. Tighten the bolts in two steps to specifications.
    4.  
    5. Connect all vacuum hoses to fittings on upper intake manifold.
    6.  
    7. Engage electrical connections at throttle body, EGR pressure sensor, intake manifolds sub harness to EEC main harness.
    8.  
    9. Install and adjust throttle linkage bracket assembly and cover.
    10.  
    11. Connect hoses from water outlet to radiator, and bypass hose from thermostat housing rear cover to intake manifold.
    12.  
    13. Connect battery negative cable.
    14.  
    15. Refill and bleed the cooling system.
    16.  
    17. Recheck ignition timing and reset engine idle speed to specification.
    18.  
    19. Run engine at fast idle and check for coolant and oil leaks.
    20.  

    3.0L Engine

    See Figures 10, 11 and 12

    The throttle body is cast integral to the upper intake manifold. To remove the upper intake manifold, refer to Fuel System for throttle body removal.

    1. Drain the cooling system (with the engine cold).
    2.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

    1. Disconnect the battery ground cable.
    2.  
    3. Depressurize the fuel system and remove the air intake throttle body as outlined in Fuel System .
    4.  
    5. Disconnect the fuel return and supply lines.
    6.  
    7. Remove the fuel injector wiring harness from the engine.
    8.  
    9. Disconnect the upper radiator hose.
    10.  
    11. Disconnect the water outlet heater hose.
    12.  
    13. If equipped with distributor ignition, disconnect the distributor cap with the spark plug wires attached. Matchmark and remove the distributor assembly.
    14.  
    15. If equipped with distributorless ignition, Label and remove the spark plug wires from the coil pack, then remove the coil pack.
    16.  
    17. Remove the valve covers. Loosen retaining nut from cylinder #3 intake valve and rotate rocker arm fulcrum away from valve retainer. Remove the pushrod.
    18.  
    19. Remove the intake manifold attaching bolts and studs (Torx® socket required).
    20.  
    21. Lift the intake manifold off the engine. Use a plastic mallet to tap lightly around the intake manifold to break it loose, if necessary. Do not pry between the manifold and cylinder head with any sharp instrument. The manifold can be removed with the fuel rails and injectors in place.
    22.  
    23. Remove the manifold side gaskets and end seals and discard. If the manifold is being replaced, transfer the fuel injector and fuel rail components to the new manifold on a clean workbench. Clean all gasket mating surfaces.
    24.  

    To install:
    1. First lightly oil all attaching bolts and stud threads. The intake manifold, cylinder head and cylinder block mating surfaces should be clean and free of old silicone rubber sealer. Use a suitable solvent to clean these areas.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 10: Silicone sealer and intake end seal application for the 3.0L engine



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    Fig. Fig. 11: Intake manifold gasket positioning for the 3.0L



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    Fig. Fig. 12: Intake manifold torque sequence for the 3.0L

    1. Apply silicone rubber sealer (D6AZ-19562-A or equivalent) to the intersection of the cylinder block assembly and head assembly at four corners as illustrated.
    2.  

    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. In high temperature/humidity conditions, the RTV will start to skin over in about 5 minutes.

    1. Install the front intake manifold seal and rear intake manifold seal, then secure them with retaining features.
    2.  
    3. Position the intake manifold gaskets in place and insert the locking tabs over the tabs on the cylinder head gaskets.
    4.  
    5. Apply silicone rubber sealer over the gasket in the same places as in Step 14.
    6.  
    7. Carefully lower the intake manifold into position on the cylinder block and cylinder heads to prevent smearing the silicone sealer and causing gasketing voids.
    8.  
    9. Install the retaining bolts. Tighten in two stages, using the sequence illustrated, first to 11 ft. lbs., then to 18 ft. lbs.
    10.  
    11. If installing a new manifold, install fuel supply rail and injectors. Refer to the necessary service procedures.
    12.  
    13. Install #3 cylinder intake valve pushrod. Apply oil to pushrod and fulcrum prior to installation. Rotate the crankshaft to place the lifter on the heel position or base circle of camshaft. Tighten to 8 ft. lbs. to seat fulcrum in cylinder head. Final bolt torque is 5 ft. lbs.
    14.  
    15. Install valve covers, fuel injector harness, throttle body assembly, hose and electrical connections.
    16.  
    17. If equipped with distributor ignition, install the distributor assembly, using the matchmarks made earlier to insure correct alignment. Install the distributor cap and spark plug wires.
    18.  
    19. If equipped with distributorless ignition, install the coil pack then install the spark plug wires to their original locations.
    20.  
    21. Install coolant hoses. Connect all vacuum lines. Reconnect fuel lines. Install fuel line safety clips.
    22.  
    23. Fill and bleed cooling system. If any engine coolant accidentally spilled into the engine while the intake was off, change engine oil and filter.
    24.  
    25. Install air cleaner hose. Connect battery ground cable. Start engine and check for coolant, oil, fuel and vacuum leaks.
    26.  
    27. If equipped with distributor ignition, verify base initial timing as outlined. Check and adjust engine idle as necessary.
    28.  

    4.0L Engine (VIN X)

    See Figures 13, 14 and 15

    The intake manifold is a 4-piece assembly, consisting of the upper intake manifold, the throttle body, the fuel supply manifold, and the lower intake manifold.

    1. Disconnect the battery ground cable.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 13: Begin the intake removal by unbolting the throttle linkage weather shield ...



    Click image to see an enlarged view

    Fig. Fig. 14: ... then remove the air intake duct from the throttle body



    Click image to see an enlarged view

    Fig. Fig. 15: Disconnect the throttle linkage, then unbolt and remove the cable bracket

    1. Remove the weather shield.
    2.  
    3. Remove the air cleaner intake duct.
    4.  
    5. Disconnect the throttle cable and bracket.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 16: Label all of the electrical and vacuum connections on the intake manifold ...



    Click image to see an enlarged view

    Fig. Fig. 17: ... then disconnect the vacuum lines ...



    Click image to see an enlarged view

    Fig. Fig. 18: ... and the electrical harness plugs

    1. Tag and unplug all vacuum lines connected to the manifold.
    2.  
    3. Tag and disconnect all electrical wires attached to the upper manifold assembly.
    4.  
    5. Relieve the fuel system pressure.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 19: Also, ensure that any brackets which are bolted to the manifold are unfastened

    1. Tag and remove the spark plug wires.
    2.  
    3. Remove the EDIS ignition coil and bracket.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 20: Remove the upper intake manifold attaching bolts ...



    Click image to see an enlarged view

    Fig. Fig. 21: ... then lift the manifold from the engine



    Click image to see an enlarged view

    Fig. Fig. 22: Stuff rags into the intake runners, then remove the old upper intake gasket; use care when scraping

    1. Remove the 6 attaching nuts and lift off the upper manifold.
    2.  

    If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the procedure to also remove the lower intake manifold.



    Click image to see an enlarged view

    Fig. Fig. 23: Disconnect the fuel supply and return lines from the injector fuel rail



    Click image to see an enlarged view

    Fig. Fig. 24: Label all of the electrical connections on the lower intake manifold ...



    Click image to see an enlarged view

    Fig. Fig. 25: ... then disconnect them. Next, remove the valve covers

    1. Disconnect the fuel supply and return lines from the injector fuel rail.
    2.  
    3. Label and disconnect all of the electrical connections on the lower manifold assembly.
    4.  
    5. Remove the valve covers.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 26: Remove the lower intake manifold attaching bolts ...



    Click image to see an enlarged view

    Fig. Fig. 27: ... then lift the manifold from the engine

    1. Remove the lower intake manifold bolts. Tap the manifold lightly with a plastic mallet and remove it.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 28: Remove the old intake gasket from the cylinder heads and engine block

    1. Clean all surfaces of old gasket material.
    2.  

    To install:
    1. Apply RTV silicone gasket material at the junction points of the heads and manifold.
    2.  

    This material will set within 15 minutes, so work quickly!

    1. Install new manifold gaskets and again apply the RTV material.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 29: Intake manifold and gasket installation for the 4.0L



    Click image to see an enlarged view

    Fig. Fig. 30: Intake manifold torque sequence for the 4.0L

    1. Position the manifold and install the nuts hand-tight. Tighten the nuts in 4 stages, using the sequence shown, to 18 ft. lbs.
    2.  
    3. Once again, apply RTV material to the manifold/head joints.
    4.  
    5. Install the valve covers using new gaskets.
    6.  

    The following procedures are for installing the upper intake manifold.

    1. Position a new gasket and install the upper manifold. Tighten the nuts to 18 ft. lbs.
    2.  
    3. Install the EDIS coil.
    4.  
    5. Connect the fuel and return lines.
    6.  
    7. Install the throttle body.
    8.  
    9. Connect all wires.
    10.  
    11. Connect all vacuum lines.
    12.  
    13. Connect the throttle linkage.
    14.  
    15. Install the weather shield.
    16.  
    17. Install the air cleaner and duct.
    18.  
    19. Fill and bleed the cooling system.
    20.  
    21. Connect the battery ground.
    22.  
    23. Run the engine and check for leaks.
    24.  

    4.0L SOHC Engine (VIN E)
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner-to-intake tube.
    4.  
    5. Remove the accelerator splash shield.
    6.  
    7. Disconnect the accelerator and, if equipped with cruise control, speed control cables from the throttle control cam.
    8.  
    9. Remove the accelerator cable retaining bracket from the upper intake manifold.
    10.  
    11. Label and disconnect all vacuum and electrical connections on the intake manifold.
    12.  
    13. Remove the eight upper intake manifold attaching bolts.
    14.  
    15. Lift up on the manifold and remove both fuel Vapor Management Valve (VMV) hoses.
    16.  
    17. Remove the upper intake manifold.
    18.  

    If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the procedure to also remove the lower intake manifold.

    1. Remove the 12 lower manifold attaching bolts.
    2.  
    3. Remove the lower intake manifold from the engine.
    4.  

    To install:
    1. Install the lower intake manifold to the engine.
    2.  
    3. Install the attaching bolts. Tighten to specification in several steps.
    4.  

    Ford does not specify a sequence, but it is recommended that you start tightening in the middle and work you way out to the ends. Repeat the tightening sequence several times until the bolts will no longer turn at the specified torque.

    The following procedures are for installing the upper intake manifold.

    1. Install the upper manifold.
    2.  
    3. Attach both VMV hoses to the manifold.
    4.  
    5. Install the attaching bolts and tighten to specification. See the note above.
    6.  
    7. Attach any vacuum and electrical connections that were removed.
    8.  
    9. Connect the accelerator cable bracket to the intake and the cable (or cables if equipped with cruise control) to the throttle cam.
    10.  
    11. Install the accelerator splash shield.
    12.  
    13. Install the air cleaner-to-intake supply tube.
    14.  
    15. Connect the negative battery cable. Run the engine until normal operating temperature is reached and check for vacuum leaks.
    16.  

    5.0L Engine

    See Figures 31 through 36

    To remove the lower intake manifold on the 5.0L engine, the camshaft synchronizer, which houses the Camshaft Position (CMP) sensor, must be removed. Refer to Driveability & Emissions Controls before starting this procedure as there are special tools necessary. If the tools are not available and you remove the CMP, the fuel injectors will not remain timed to the engine and the vehicle will not run.

    1. Disconnect the negative battery cable.
    2.  
    3. Drain the cooling system.
    4.  


    CAUTION
    When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

    1. Remove the air cleaner outlet tube.
    2.  
    3. Disconnect the crankcase ventilation hose from the throttle body.
    4.  
    5. Remove the throttle body shield then disengage the cables from the throttle shaft.
    6.  
    7. Label and disconnect any electrical components or vacuum lines attached to the upper intake manifold.
    8.  
    9. Remove the accelerator cable brackets from the manifold and position aside.
    10.  
    11. If equipped, disconnect the EGR spacer (or throttle body) coolant hoses.
    12.  
    13. Label and remove the spark plug wires from the coil packs.
    14.  
    15. Disconnect the ignition coil wiring harness plug.
    16.  
    17. Unbolt and remove the coil packs from the engine.
    18.  
    19. Remove the intake cover plate to gain access to the two long upper intake manifold attaching bolts.
    20.  
    21. Remove any wires or loom holders from the upper manifold.
    22.  



    Click image to see an enlarged view

    Fig. Fig. 31: Upper intake manifold bolt loosening sequence

    1. Loosen and remove the upper intake manifold attaching bolts in the sequence given.
    2.  
    3. Remove the upper manifold and its gasket.
    4.  

    If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the procedure to also remove the lower intake manifold.


    CAUTION
    Fuel lines on fuel injected vehicles will remain pressurized after the engine is shut off. Fuel pressure must be relieved before servicing the fuel system.

    1. Properly relieve the fuel system pressure then disconnect the fuel supply and return lines from the fuel supply manifold.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 32: Hot water tube assembly and its mounting points

    1. Disconnect the heater hoses from the hot water tube. Also remove the tube from the lower manifold.
    2.  
    3. Label and disconnect any electrical components, sensors or vacuum lines connected to the lower manifold.
    4.  
    5. Disconnect the upper radiator hose from the water outlet.
    6.  
    7. Loosen the water pump bypass hose clamp at the pump.
    8.  
    9. Remove the rear engine ground strap.
    10.  
    11. Remove the camshaft synchronizer with the Camshaft Position (CMP) sensor installed. Refer to Driveability & Emissions Controls .
    12.  



    Click image to see an enlarged view

    Fig. Fig. 33: Lower intake manifold loosening sequence

    1. Loosen and remove the lower manifold attaching bolts in the sequence given.
    2.  
    3. Remove the lower manifold and its gasket from the engine.
    4.  

    To install:
    1. Ensure that all of the gasket mating surfaces are clean and free or grease, oil or dirt. Also ensure that the EGR passages in the manifolds and heads are clear.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 34: Intake manifold gasket and sealant points. Note that points (1) and (5) are sealed with RTV silicone

    1. Apply a 1 / 16 in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.
    2.  
    3. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.
    4.  
    5. Apply a 1 / 16 in. (1.6mm) bead of sealer to the outer end of each intake manifold seal for the full width of the seal. Make sure the silicone sealer will not fall into the engine and possibly block oil passages.
    6.  
    7. Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads. Also, ensure that the water pump bypass hose is installed at the same time.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 35: Lower intake manifold bolt tightening sequence

    1. Install the lower manifold attaching bolts and tighten, in sequence shown, to specification in two steps as follows:
      1. Tighten all bolts to 5-10 ft. lbs. (6-14 Nm).
      2.  
      3. Tighten all bolts to 4-6 ft. lbs. (12-17 Nm).
      4.  

    2.  
    3. Install the camshaft synchronizer. Refer to Driveability & Emissions Controls .
    4.  
    5. Install the rear engine ground strap.
    6.  
    7. Tighten the water pump bypass hose clamp at the water pump.
    8.  
    9. Install the upper radiator hose to the water outlet.
    10.  
    11. Connect any electrical components or vacuum lines which were removed from the lower manifold.
    12.  
    13. Install the hot water tube to the engine, and connect the heater hose to the tube.
    14.  
    15. Connect the fuel lines, then temporarily connect the negative battery cable. Cycle the ignition to pressurize the fuel system and check for leaks. Turn the ignition key back and forth (from ON to OFF ) at least 6 times, leaving the key ON for 5 seconds each time. If no leaks are found, disconnect the negative battery cable and continue the installation.
    16.  

    The following procedures are for installing the upper intake manifold.



    Click image to see an enlarged view

    Fig. Fig. 36: Upper intake manifold bolt tightening sequence

    1. Install the upper intake manifold using a new gasket. Tighten the attaching bolts in the sequence given to the proper specification.
    2.  
    3. Install the intake cover plate.
    4.  
    5. Install the ignition coils to the engine and connect the harness plug and spark plug wires to them.
    6.  
    7. If equipped, install the EGR spacer (throttle body) coolant hoses.
    8.  
    9. Install the accelerator cable brackets and cables to the intake and throttle shaft.
    10.  
    11. Connect any electrical components or vacuum lines removed from the upper manifold.
    12.  
    13. Install the throttle body shield.
    14.  
    15. Install the air cleaner outlet tube to the throttle body.
    16.  
    17. Refill and bleed the cooling system.
    18.  
    19. Connect the negative battery cable then start and run the engine until it reaches normal operating temperatures. Check for leaks.
    20.  

     
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