Lower Intake Manifold Replacement L26

Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

1. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .
2. Remove the generator brace. Refer to Generator Brace Replacement .
3. Remove the drive belt tensioner with the heater water bypass inlet pipe. Refer to Drive Belt Tensioner Replacement .



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. Remove the radiator inlet hose from the water outlet housing. Refer to Radiator Inlet Hose Replacement .



7. Disconnect the engine coolant temperature (ECT) sensor electrical connector.



8. Remove the generator brace bracket bolts.
9. Remove the generator brace bracket.



10. Remove the lower intake manifold bolts.
11. Remove the lower intake manifold.



12. Remove the lower intake manifold seals.



13. Remove the lower intake manifold gaskets.



14. If replacing the lower intake manifold, remove the water outlet housing bolt, stud and the water outlet housing.
15. If replacing the lower intake manifold, remove the ECT sensor.
16. Inspect the flatness of the inlet flanges.
17. Clean the intake manifold gasket mating surfaces.
18. Clean the intake manifold bolts and bolt holes of adhesive compound.

Notice: Refer to Fastener Notice in the Preface section.

1. If removed, install the ECT sensor.

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




4. Install the lower intake manifold gaskets.



5. Apply sealer to the ends of the intake manifold seals. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
6. Install the lower intake manifold seals.




Notice: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.

7. Install the lower intake manifold.
8. Apply thread lock compound to the two hidden bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.



9. Install the lower intake manifold bolts (1-12).

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




10. Install the generator brace bracket.
11. Install the generator brace bracket bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).




12. Connect the ECT sensor electrical connector.



13. Install the radiator inlet hose to the water outlet housing. Refer to Radiator Inlet Hose Replacement .



14. Install the EGR outlet pipe (1) to the lower intake manifold.
15. Install the EGR outlet pipe bolt (2) to the lower intake manifold.

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




16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
17. Install the generator brace. Refer to Generator Brace Replacement .
18. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
19. Inspect for fluid or vacuum leaks.

Lower Intake Manifold Replacement L32

1. Drain the cooling system. Refer to Cooling System Draining and Filling .
2. Remove the supercharger. Refer to Supercharger Replacement .
3. Remove the radiator inlet hose from the water outlet housing. Refer to Radiator Inlet Hose Replacement .



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.

Notice: Refer to Fastener Notice in the Preface section.

1. If removed, install the ECT sensor.

Tighten
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
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. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
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
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
Tighten the bolt to 29 N·m (21 lb ft).




12. Install the radiator inlet hose to the water outlet housing. Refer to Radiator Inlet Hose Replacement .
13. Install the supercharger. Refer to Supercharger Replacement .
14. Fill the cooling system. Refer to Cooling System Draining and Filling .
15. Inspect for fluid or vacuum leaks.