Intake Manifold: Service and Repair

Fig. 11 Intake manifold drain tube removal & installation:

Fig. 12 Removal & installation of intermediate adapter, pump adapter & seal:

REMOVAL
1. Disconnect battery ground cable(s), then remove air cleaner.
2. Drain radiator coolant, then disconnect upper radiator hose from water outlet, and heater hoses from intake manifold.
3. Remove fuel injection pump. Refer to ``Injection Pump, Replace.''
4. Disconnect wiring from engine accessories.
5. If equipped with cruise control, remove servo.
6. If equipped with A/C, remove compressor and braces. Position aside.
7. Remove alternator assembly.
8. Disconnect engine mounting strut.
9. Remove fuel lines, filter and brackets. Plug all openings.
10. Disconnect glow plug controller and sending units wire connectors.
11. Disconnect heat shield from exhaust pipe crossover.
12. Using a suitable back-up wrench, remove left (forward) injection lines and plug all openings.
13. Disconnect T.V. and throttle cables from bracket.
14. Remove intake manifold drain tube, Fig. 11.
15. Remove injection pump intermediate adapter, pump adapter and seal, Fig. 12.
16. Remove intake manifold.

Fig. 13 Intake manifold installation:

Fig. 14 Intake manifold torquing sequence:

INSTALLATION
1. Thoroughly clean machined surfaces of cylinder head and intake manifold, ensuring neither surface becomes gouged or scratched. Clean all bolts and bolt holes.
2. Using a suitable sealer, coat both sides of the manifold to head sealing gasket surface, and place in position, Fig. 13.
3. Install end seals, ensure ends are positioned under cylinder heads. Apply RTV sealer to each end of seal, Fig. 13. The end seals and mating surfaces must be dry to prevent gasket slippage.
4. Carefully position intake manifold on engine.
5. Lubricate intake manifold bolts entire length with lubricant 1052080 or equivalent.
6. Install bolts. Torque to specifications following sequence shown in Fig. 14, to 15 ft. lbs. Then retorque to specifications.
7. Reverse steps 1 through 15 of removal procedure to complete installation.