Intake Manifold

Intake Manifold Installation:

REMOVE OR DISCONNECT
1. Drain the coolant.
2. Battery negative cable.
3. Air cleaner.
4. Wires and hoses at the TBI unit and manifold.
5. Fuel lines at the TBI unit.
6. Cables from the TBI unit.
7. Spark plug wires at the spark plugs.
8. Wires at the coil.
9. Distributor cap with spark plug wires.
10. Distributor hold down bracket.
11. Distributor
12. EGR vacuum line.
13. Evaporative emission hoses.
14. Pipe brackets from the valve covers.
15. Valve covers.
16. Upper radiator hose.
17. Heater hose.
18. Coolant sensor connectors.
19. Intake manifold bolts and nuts.
20. Intake manifold.
21. 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. RTV to the front and rear sealing surfaces on the block. Apply a 5 mm (3/16-inch) bead of RTV (part number 1052917 or equivalent) 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 (1/4-inch) 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 Nm (23 ft. lbs.) in the sequence shown in figure 10. Then re-torque using the same sequence.
5. Heater hose and radiator hose to the manifold.
6. Valve 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.