Intake Manifold: Service and Repair

INTAKE MANIFOLD

Remove

1. Battery negative cable
2. Relieve fuel pressure.
3. Drain coolant
4. Throttle and cruise control cables from throttle body and cable bracket
5. TV cable, if equipped, from throttle body and bracket.
6. Bracket from plenum
7. Electrical connectors at:

- Coolant temperature sensor.
- TPS. MAT.
- IAC. MAP.

8. Air intake duct from throttle body.
9. Vacuum hoses from throttle body and plenum.
10. Heater hoses at throttle body, two places.
11. Power brake vacuum booster fitting at plenum.
12. Runner to plenum bolts and plenum from engine.
13. Vacuum harness from EGR solenoid.
14. EGR solenoid assembly from coolant outlet.
15. EGR valve from intake manifold.
16. injector harness retaining nuts.
17. Runner to manifold bolts and runners.
18. Injector harness connectors.
19. Release fuel rail pressure.
20. Fuel lines.
21. Fuel rail and injector assembly.
22. Distributor.
23. Radiator upper hose at coolant outlet.
24. AIR pump brace.
25. EGR valve pipe and set aside.
26. PCV valve hose from manifold.
27. Crankcase vent tube from manifold.
28. Intake manifold bolts and manifold.


Install

Clean

- Gasket and sealing surfaces on manifold, block, and cylinder heads. Thorough removal of all old gasket material and RTV will help ensure a leak-free installation.

1. Gaskets on cylinder heads. Coolant passage restrictors in gaskets to be positioned at rear of engine. Bend gasket tab flush with front face of cylinder head.
2. Place a 5 mm (0.2 in.) bead of RJV sealant, GM P/N 1052915 or equivalent, on the front and rear

Important: At time of intake manifold installation, sealant must be wet to touch when manifold bolts are tightened.





3. Intake manifold.
4. Manifold bolts following the tightening sequence.

Tighten
- All bolt positions except 1 and 4 to 47 Nm (35 lbs. ft.).
- Position 1 and 4 to 61 Nm (45 lbs. if.).

5. Crankcase vent tube.
6. PCV valve hose to manifold.
7. FOR valve pipe.
8. AIR pump brace.
9. Radiator upper hose at coolant outlet.
10. Distributor.
11. Fuel rail and injector assembly.
12. Fuel lines.
13. Injector harness connectors.
14. Runners, gaskets and runner to manifold bolts.

Tighten
- Bolts to 34 Nm (25 lbs. ft.).

15. Injector harness and nuts.

Tighten
- Harness nuts to 10 Nm (90 lbs. in.).

16. EGR valve to intake manifold.

Tighten
- EGR valve bolt to 16 Nm (12 lbs. ft.).

17. EGR solenoid assembly to coolant outlet.

Tighten
- Coolant outlet bolt to 34 Nm (25 lbs. ft.).

18. Vacuum harness to EGR solenoid.
19. Plenum and runner to plenum bolts.

Tighten
- Bolts to 34 Nm (25 lbs. ft.).

20. Power brake vacuum fitting at plenum.

Tighten
- Fitting to 12 Nm (108 lbs. in.).

21. Heater hoses at throttle body.
22. Vacuum hoses.
23. Air intake duct.
24. Electrical connectors at the following sensors:

- MAP. TPS.
- MAT. IAC.
- Coolant temperature sensor.

25. Cable bracket to plenum.
26. TV cable, if equipped, to bracket and throttle body.
27. Throttle and cruise control cables to bracket and throttle body.
28. Refill coolant.
29. Battery negative cable.