Intake Manifold: Service and Repair

INTAKE MANIFOLD REPLACEMENT

Removal

1. Battery negative cable.
2. Air cleaner.

- Drain the cooling system.

3. Heater pipe and upper radiator hose at the intake manifold.
4. Generator rear brace at the manifold.
5. Vacuum hoses at the manifold, TBI unit, and EGR valve.
6. Electrical connections at the manifold and TBI unit.
7. Fuel line(s) at the TB unit.
8. Accelerator, cruise control, and TVS cables, as equipped.
9. Distributor.
10. Air conditioning compressor rear bracket.
11. Brake booster vacuum pipe.
12. Coil wires.
13. Emission control sensors and bracket on right side.
14. Fuel line bracket at rear of manifold. Move the fuel lines aside.
15. Bracket at rear of belt idler.
16. TBI unit (if necessary).
17. Intake manifold bolts.
18. Intake manifold.
19. Gaskets and clips, if equipped (some TBI engines).

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

1. Gaskets to the cylinder head. On TBI engines so equipped, also install the clips over the gaskets, to the rib between the intake ports. Then apply a dot of RTV to the upper side of the clip.





2. RTV to the front and rear sealing surfaces on the block. Apply a 5 mm (3/16 inch) bead of RTV (part number 1052366 or equivalent) to the front and rear of the block. Extend the bead 13 mm (1/2 inch) up each cylinder head to seal and retain the gaskets.
3. Intake manifold to the engine.
4. Intake manifold bolts.





Tighten

Intake manifold bolts to 48 Nm (35 ft. lbs.). Use the tightening sequence.

5. TB unit (if removed).

6. Bracket at rear of belt idler
7. Fuel line bracket at rear of manifold.
8. Emission control sensors and bracket.
9. Coil wires.
10. Brake booster vacuum pipe.
11. Air conditioning compressor rear bracket.
12. Distributor.
13. Accelerator, cruise control, and TVS cables, as equipped.
14. Fuel line(s) at the TB unit.
15. Electrical connections.
16. Vacuum hoses.
17. Generator brace.
18. Heater pipe and upper radiator hose.
19. Air cleaner
20. Battery negative cable.

- Fill the cooling system with the proper quantity and grade of coolant.