Intake Manifold: Service and Repair

Remove or Disconnect
1. Negative battery cable.
2. Engine cover.
3. Air cleaner and heat stove tube.
^ Drain the cooling system.

4. Distributor.
5. Accelerator, cruise control and TVS cables and bracket.
6. Cruise control transducer (if equipped).
7. Air conditioning compressor; set aside.
8. Generator bracket at the manifold.
9. Idler pulley bracket at the manifold.
10. Fuel and vacuum lines and electrical connections at the TBI unit and manifold.
11. Heater pipe.
12. Upper radiator hose.
13. Power brake vacuum pipe.
14. Coil wires.
15. EGR vacuum line.
16. Sensors with bracket on right side.
17. Wiring harness on right side; move out of the way.
18. Transmission dipstick tube (if equipped).
19. Intake manifold bolts.
20. Intake manifold and 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
1. Gaskets to the cylinder head. (Port blocking plate to the rear).
2. RTV to the front and rear sealing surfaces on the block. Apply a 5 mm (3/16-inch) bead of RTV (part number 1052366 or equivalent) to the front and rear of the block. Extend the bead 13 mm (1/2-inch) up each cylinder head to seal and retain the gaskets.
3. Intake manifold to the engine.
4. Intake manifold bolts.
Tighten
^ Intake manifold bolts to 46 N.m (35 ft. lbs.). Use the tightening sequence.

5. Transmission dipstick tube (if equipped).
6. Wiring harness.
7. Sensors with bracket.
8. EGR vacuum line.
9. Coil wires.
10. Power brake vacuum pipe.
11. Upper radiator hose.
12. Heater pipe.
13. Fuel and vacuum lines and electrical connections at the TBI and manifold.
14. Idler pulley bracket
15. Generator bracket.
16. Air conditioning compressor.
17. Cruise control transducer (if equipped).
18. Accelerator, cruise control and TVS cables and bracket.
19. Distributor.
20. Air cleaner and heat stove tube.
21. Engine cover.
22. Negative battery cable
^ Fill the cooling system with the proper coolant.