Intake Manifold: Service and Repair

Remove or Disconnect
1. Negative battery cable
2. Air cleaner assembly
3. Drain engine coolant as necessary
4. Cross car brace
5. Accessory drive belt
6. P/S and tensioner bracket assembly and reposition toward front of engine
7. Generator and bracket
8. Disconnect (3) cables at throttle body and remove return spring.
9. Wire connections and reposition
^ Distributor
^ Oil pressure switch
^ Coolant sensor
^ EGR solenoid
^ ISC motor
^ TPS
^ AIR solenoid
^ Injectors
^ MAT sensor

10. Remove MAP hoses
11. Upper radiator hose and heater hoses at thermostat housing
12. A/C hose bracket
13. Distributor cap, spark plug wire protectors and reposition cap
14. Mark distributor rotor position and remove distributor
Important
^ Do not crank or in any other way rotate crankshaft with the distributor removed.

CAUTION: Failure to properly depressurize the fuel system may result in fire or personal injury.
15. Disconnect fuel lines at transmission bracket.
16. Fuel and vacuum lines from throttle body
17. Loosen vacuum line clip at lift bracket
18. Vacuum supply line at throttle body and transmission modulator line
19. Remove EGR solenoid and bracket assembly
20. Valve covers
21. Rocker arms and push rods
Important
^ Push rods should be marked or retained in sequence so that they may be reinstalled in their original positions

22. Remove brackets at P/S and AIR pipes
23. Remove right front lift bracket
24. Remove rear lift brackets
25. Intake manifold bolts
26. Intake manifold
27. Gaskets, seals and discard
Clean
1. Sealing surfaces of:
^ Intake manifold
^ Cylinder head
^ Cylinder block

Install or Connect
1. New end seals
2. RTV 1052366 to four corners where end seals will meet side gaskets
3. New intake to cylinder head gaskets
4. RTV 1052366 to four corners of end seals
5. Intake manifold
6. Intake manifold bolts
Tighten
^ Intake manifold bolts in sequence

7. Push rods and rocker arm assemblies
8. Valve covers
9. EGR solenoid and bracket assembly
10. Install lift brackets