Intake Manifold: Service and Repair

Protecting Intake Ports:

Remove or Disconnect

Tool Required:
J 29664 Manifold Cover Set

1. Battery cables.

2. Engine cover.

3. Air cleaner.

4. EGR/EPR solenoids and bracket from the intake manifold studs.

5. CDR valve.

6. EGR and crankcase ventilation hoses.

7. Air conditioning compressor rear bracket (if equipped).

8. Fuel line bracket and ground strap.

9. Fuel filter bracket at the intake manifold.

10. Intake manifold bolts and fuel line clips. On models with gear driven vacuum pumps, it may be necessary to loosen the vacuum pump clamp bolt and turn the pump to provide access to an intake manifold bolt.

11. Intake manifold and gasket.

Important
^ If any further service work is to be done, cover the intake ports with J 29664.

Clean
^ Gasket surfaces on intake manifold and cylinder heads.

Intake Manifold:

Install or Connect

1. New gaskets. Be sure to use the correct gasket. The gaskets for light duty emissions models have openings for the EGR ports; the gaskets for heavy duty emissions models do not.

2. Intake manifold.

3. Intake manifold bolts and fuel line clips.

Tighten
^ Intake manifold bolts to 42 N.m (32 ft. lbs.). Use tightening sequence illustrated.

^ Rotate the vacuum pump to the proper position and tighten the clamp bolt (on models with gear driven vacuum pumps).

4. Fuel filter bracket.

5. Fuel line bracket and ground strap.

6. Air conditioning compressor rear bracket (if equipped).

7. EGR and crankcase ventilation hoses.

8. CDR valve.

9. EGR/EPR solenoids and bracket.

10. Air cleaner.

11. Engine cover).

12. Battery cables.