Intake Manifold: Service and Repair

1. Relieve fuel pressure, then disconnect battery ground cable and drain coolant from engine.
2. Disconnect accelerator cable.
3. Remove air cleaner assembly and heat stove duct from heat shield.
4. Disconnect all vacuum lines from intake manifold.
5. Remove thermactor belt from pulley, thermactor hose and thermactor pump from engine.
6. Remove exhaust pipe to exhaust manifold nuts and disconnect exhaust pipe from exhaust manifold.
7. Remove exhaust manifold heat shield.
8. Disconnect Exhaust Gas Oxygen (EGO) sensor electrical connector.
9. Disconnect thermactor check valve hose from tube assembly. Remove Exhaust Gas Recirculation (EGR) valve bracket nuts and EGR valve bracket.
10. Disconnect water inlet hose from intake manifold.
11. Disconnect EGR hose from EGR valve.
12. Remove bolts, intake manifold and gasket from engine.

Fig. 5 Intake Manifold Bolt Tightening Sequence:

13. Reverse procedure to install. Torque intake manifold bolts in two steps and in sequence shown: first to 5-7 ft lb, then to 15-22 ft lb.