Intake Manifold: Service and Repair

REMOVE OR DISCONNECT
1. Disconnect battery negative cable.
2. Disconnect the accelerator and T.V. cable bracket at the plenum.
3. Disconnect the throttle body at the plenum.
4. Disconnect the E.G.R. pipe at the E.G.R. valve.
5. Remove the plenum.
6. Disconnect the fuel inlet and return pipes at the fuel rail.
7. Disconnect the serpentine belt.
8. Remove the power steering pump mounting bracket.
9. Disconnect the heater pipe at the power steering pump bracket.
10. Disconnect the wires at the alternator.
11. Remove the alternator.
12. Disconnect the wires at the cold start injector.
13. Remove the cold start injector at the intake manifold.
14. Disconnect the idle air vacuum hose at the throttle body.
15. Disconnect the wires at the injectors.
16. Remove the fuel rail.
17. Remove the breather tube.
18. Remove the runners.
19. Disconnect the coil wires at the bracket.
20. Remove both rocker arm covers.
21. Drain the cooling system.
22. Disconnect the radiator hose at the thermostat outlet.
23. Disconnect the heater pipe at the thermostat housing.
24. Disconnect the wires at the thermostat housing.
25. Remove distributor.
26. Remove thermostat housing.
27. Remove intake manifold bolts.
28. Remove the intake manifold.

INSTALL OR CONNECT
1. Clean sealing surfaces cylinder case front and rear ridges with degreaser. Place a 5 mm diameter (3/16") bead of RTV l0529l7 or equivalent, on each ridge.
2. Install new intake gaskets on cylinder heads. Hold in place by extending ridge RTV bead up 6mm onto the gasket ends. The new intake gaskets will have to be cut, where indicated, to install behind push rods. Cut only those areas that are necessary.
3. Install intake manifold on engine. Make sure areas between case ridges and intake are completely sealed.
4. Install manifold retaining bolts and nuts and torque in the sequence shown to 31 Nm (23 ft. lb.).
5. Install thermostat housing.
6. Install distributor.
7. Reconnect wires at thermostat housing.
8. Reconnect heater pipe at the thermostat housing.
9. Reconnect the radiator hose at the thermostat outlet.
10. Fill cooling system.
11. Install rocker arm cover as previously outlined.
12. Reconnect coil wires at the bracket.
13. Install runner.
14. Install breather tube.
15. Install the fuel rail.
16. Reconnect the wires at the injectors.
17. Reconnect the idle air vacuum hose at the throttle body.
18. Install cold start injector.
19. Install alternator.
20. Reconnect the wires at the alternator.
21. Reconnect the heater pipe at the P/S pump bracket.
22. Install the P/S pump mounting bracket.
23. Install the serpentine belt.
24. Reconnect the fuel inlet and return pipes at the fuel rail.
25. Install plenum.
26. Install E.G.R.
27. Install throttle body at the plenum.
28. Reconnect the accelerator and T.V. cable bracket at the plenum.
29. Reconnect the battery negative cable.
30. Start engine, set initial timing. After set, torque distributor hold down clamp bolt to 34 Nm (25 ft. lb.). Recheck timing after torquing bolt.
31. Let engine run until radiator upper hose becomes hot (thermostat open).
32. With engine idling, add coolant to radiator, if necessary, until level reaches bottom of filler neck.
33. Install radiator cap, making sure arrows on cap line up with overflow tube.