Intake Manifold: Service and Repair

1. Disconnect battery ground cable.
2. Disconnect accelerator and T.V. cable bracket at plenum.
3. Disconnect throttle body at plenum.
4. Disconnect E.G.R. pipe at E.G.R. valve, then remove plenum.
5. Disconnect fuel inlet and return pipes at fuel rail.
6. Disconnect serpentine belt, then remove power steering pump mounting bracket.
7. Disconnect heater pipe at power steering pump bracket.
8. Disconnect electrical connectors at alternator and remove alternator.
9. Disconnect electrical connector at cold start injector and remove injector.
10. Disconnect idle air vacuum hose at throttle body and the electrical connectors at injectors.
11. Remove fuel rail, breather tube and the runners.
12. Disconnect coil wires at bracket.
13. Remove both rocker arm covers and drain cooling system.
14. Disconnect radiator hose at thermostat outlet and the heater pipe at thermostat housing.
15. Disconnect electrical connectors at thermostat housing.
16. Remove distributor, thermostat housing, intake manifold attaching bolts and the intake manifold.

Fig. 4 Installing intake manifold gasket:

17. Reverse procedure to install, noting the following:
a. When installing gaskets, install only on right or left side as marked.
b. Clean cylinder case sealing surface front and rear ridges and apply a 3/16 inch bead of suitable sealant on each ridge.
c. Install new intake gaskets on cylinder heads, holding in place by extending ridge sealant bead up 6 mm onto onto gasket ends. On 1982---86 models new intake gaskets will have to be cut where indicated, Fig. 4, to install behind push rods. Cut only those areas that are necessary.
d. When installing intake manifold, ensure areas between case ridges and manifold are completely sealed.
e. Install manifold retaining bolts and nuts, torquing to specifications. Refer to Specifications.
f. After completing installation, start engine and set initial timing, torque distributor hold-down clamp bolt to 25 ft lb and recheck timing.