Intake Manifold: Service and Repair

Remove or Disconnect
1. Air cleaner assembly
2. Drain cooling system.
3. Negative battery cable.
4. Tower-to-tower brace.
5. Accessory drive belt.
6. Power Steering pump pressure and return lines at reservoir.
7. Power steering pump and bracket.
8. Generator and mounting bracket with cruise control servo attached.
9. Fuel rail covers.
10. Cruise control and throttle cables at throttle body. Remove cable bracket at manifold.
11. Disconnect electrical connectors and vacuum hoses.
12. Upper radiator hose at thermostat housing.
13. Heater hose at thermostat housing.
14. Distributor cap and spark plug wires.
15. Mark distributor rotor position and remove distributor.
Important
^ Do not crank or otherwise rotate crankshaft with distributor removed.

CAUTION: Failure to properly depressurize the fuel system may result In fire or personal Injury.
16. Fuel lines at fuel rail.
17. Fuel line bracket at transaxle.
18. Brake booster vacuum hose, PCV hose and vacuum modulator hose.
19. Vacuum lines at transaxle bracket.
20. Cruise control cable at bracket near servo.
21. Both valve covers
22. Rocker arm supports from both heads with rocker arms attached.
Important
^ Pushrods should be marked or retained in sequence so that they may be installed in their original positions.

23. Intake manifold bolts and manifold.
Clean
1. Sealing surfaces of:
^ Intake manifold
^ Cylinder heads
^ Crankcase

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

6. Pushrods and rocker arm assemblies.
7. Valve covers
8. Cruise control cable at bracket near servo.
9. Vacuum lines at transaxle bracket.
10. Vacuum lines for brake booster, PCV and trans vacuum modulator.
11. Fuel lines at fuel rail and retainer bracket at transaxle.
12. Ignition distributor in original position.
13. Distributor cap and plug wires.
14. Heater hose and radiator hose at thermostat housing.
15. Misc. electrical connectors and vacuum hoses.
16. Cruise control and throttle cables at throttle body.
17. Cable bracket to manifold.
18. Fuel rail covers.
19. Generator mounting bracket.
20. Power steering pump and bracket.
21. Pressure and return hoses to steering pump.
22. Accessory drive belt.
23. Tower-to-tower brace.
24. Negative battery cable.
25. Refill cooling system.
26. Start engine check for leaks and correct ignition timing.
27. Bleed power steering system
28. Perform idle learn procedure
29. Air cleaner.