Intake Manifold: Service and Repair

INTAKE MANIFOLD REPLACEMENT




Remove or Disconnect (Figure 10)


- Drain the coolant.

1. Battery negative cable.
2. Air cleaner.
3. Wires and hoses at the TBI unit and manifold.
4. Fuel lines at the TBI unit.
5. Cables from the TBI unit.
6. Spark plug wires at the spark plugs.
7. Wires at the coil.
8. Distributor cap with spark plug wires.
9. Distributor hold down bracket
10. Distributor
11. EGR vacuum line.
12. Evaporative emission hoses.
13. Pipes brackets from the rocker arm covers.
14. Rocker arm covers.
15. Upper radiator hose.
16. Heater hose.
17. Coolant sensor connectors.
18. Intake manifold bolts and nuts.
19. Intake manifold.
20. Gaskets.


Clean

- Old gasket and RTV from the block, heads and intake manifold. Remove all RTV that is loose or will cause interference at assembly.
- Excessive carbon deposits from the exhaust and EGR passages.
- Excessive scale and deposits from the coolant passages.

Inspect

- Manifold for cracks and gasket surface damage.





Install or Connect (Figure 10)
1. RTV to the front and rear sealing surfaces on the block (Figure 10). Apply a 5 mm (0.197") bead of RTV to the front and rear of the block as shown.
- Make sure that no oil or water is present on the surfaces to be sealed.
2. Gaskets to the cylinder head.
- Gaskets are marked right side or left side. Use them only as indicated to maintain design efficiency of the engine.
- Hold the gaskets in place by extending the bead of RTV 6 mm (0.236") up onto the gasket ends from the block sealing surfaces.
- The new gaskets will have to be cut where indicated to install behind the pushrods. Cut only the areas where necessary.
3. Intake manifold.
- Make sure the areas between the case ridges and the intake manifold are completely sealed.
4. Intake manifold bolts and nuts.
- Tighten Nuts and bolts to 31 N.m (23 lb. ft.) in the sequence shown in Figure 10. Then re-torque using the same sequence.
5. Heater hose and radiator hose to the manifold.
6. Rocker arm covers.
7. Coolant sensor connectors.
8. Pipe brackets.
9. Distributor, cap and wires.
10. Fuel lines.
11. Cables at the TBI unit.
12. All necessary wires and hoses.
13. Air cleaner.
14. Battery cables.
15. Proper quantity and grade of coolant.