Intake Manifold: Service and Repair

REMOVAL AND INSTALLATION
1. Drain cooling system, then remove air cleaner with intake duct assembly and crankcase ventilation hose.
2. Disconnect accelerator cable and speed control linkage (if equipped) from throttle body. Remove accelerator cable bracket, Disconnect main engine harness connector.
3. Disconnect high tension lead and wire harness from ignition coil.
4. Disconnect ignition wires from spark plugs, then wire clips from rocker arm cover attaching studs.
5. Remove distributor cap and ignition wires as an assembly.
6. Disconnect fuel inlet and return lines from fuel rail.
7. Remove distributor and disconnect evaporative vacuum hose from the throttle body.
8. Disconnect upper radiator hose from coolant outlet housing.
9. Disconnect electrical connector from coolant temperature sending unit, then remove heater hose from intake manifold.
10. Remove water pump bypass hose from coolant outlet housing.
11. Remove intake manifold attaching bolts, then manifold as follows:
a. Remove EGR tube from valve, then the upper intake manifold and throttle body as an assembly. Disconnect crankcase vent hose from rocker arm cover.
b. Remove lower intake manifold assembly.
c. It may be necessary to carefully pry the intake manifold from the cylinder heads. Remove manifold gaskets and seals and discard intake manifold attaching bolt sealing washer.

Fig. 13 Intake Manifold Installation:

Fig. 14 Intake Manifold Bolt Tightening Sequence:

12. Reverse procedure to install. Apply sealer as shown in Fig. 13. Tighten manifold attaching bolts to 23-25 ft. lbs. in sequence shown in Fig. 14.