Intake Manifold Assembly; Removal - Mercury MerCruiser Service Manual

Engine Disassembly

Intake Manifold Assembly

NOTE: The intake manifold may be removed as an assembly. Unless service is required, it is not necessary to remove
individual intake manifold components other than as outlined. See Section 5 for disassembly, cleaning, inspection, and
assembly of individual intake manifold components.

Removal

1. Remove the fuel injectors with the fuel rail. Refer to Section 5A ‑ Fuel Rail.
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
IMPORTANT: Do not allow dirt or debris to enter the fuel system. Seal the ends of the open fuel lines.
2. Remove the alternator. Refer to Section 4C ‑ Alternator Removal.
3. Disconnect any other items that interfere with the removal of the intake manifold.
4. Remove the eight intake manifold bolts.
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Left side shown
a - Intake manifold bolts
IMPORTANT: It may be necessary to pry the intake manifold away from the cylinder heads and block. Use extreme care to
prevent damage to the sealing surfaces.
Page 3A-24
WARNING
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© 2016 Mercury Marine
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90-8M0099748 eng DECEMBER 2015