Intake Manifold: Service and Repair

Intake Manifold (Right):

Intake Manifold (Left):

REMOVE OR DISCONNECT
1. Negative battery 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, Throttle body injection (TBI) unit, and EGR valve.
6. Electrical connections at the manifold and TBI unit.
7. Fuel lines at the TBI unit.
8. Accelerator and cruise control cables (if 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 pulley.
16. TBI unit (if necessary).
17. Intake manifold bolts.
18. Intake manifold.
19. Gaskets and clips.

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.

Intake Manifold (Right):

Intake Manifold (Left):

INSTALL OR CONNECT
1. Gaskets to the cylinder head. Make sure the tab and/or arrow faces the front of the engine. The side stamped "This Side Down" must face the cylinder head.
2. RTV to the front and rear sealing surfaces on the block. Apply a 5mm (3/16-inch) bead of RTV (GM P/N 1052289 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.

Intake Manifold Bolt Tightening Sequence:

4. Intake manifold bolts. Tighten intake manifold bolts to 48 Nm (35 lbs. ft.) using the tightening sequence shown.
5. TBI. 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 and cruise control cables (if equipped).
14. Fuel lines to the TBI unit.
15. Electrical connections.
16. Vacuum hoses.
17. Generator brace.
18. Heater pipe and upper radiator hose.
19. Air cleaner.
20. Negative battery cable.
- Fill the cooling system with the proper quantity and grade of coolant.