Part 3

Valve Rocker Arm Cover Clean and Inspect

Caution: Wear safety glasses in order to avoid eye damage.




1. Clean the valve rocker arm cover in cleaning solvent.
2. Dry the valve rocker arm cover with compressed air.
3. Inspect the valve rocker arm cover for the following:
- Damage to the PCV valve grommet (1)
- Damage to the bolt holes (2)
A damaged valve rocker arm cover may interfere with the valve rocker arms.
- Damage to the exterior of the valve rocker arm cover (3)
- Gouges or damage to the sealing surface (4)
- Damage to the oil fill tube grommet (5)
- Restrictions to the ventilation system passages

Oil Pan Clean and Inspect




1. Remove the oil pan baffle bolts and the oil pan baffle.

Caution: Wear safety glasses in order to avoid eye damage.




2. Clean the oil pan and oil pan baffle in cleaning solvent.
3. Dry the oil pan and oil pan baffle with compressed air.
4. Inspect the oil pan for the following:
- Gouges or damage to the oil pan sealing surfaces (1)
- Damage to the threaded holes (2)
- Damaged oil pan drain hole threads (3)
- Damage to the oil pan baffle
- Damage to the exterior of the oil pan
A damaged oil pan may interfere with the proper position of the oil pump screen, or may not distribute oil properly in the oil pan sump area.




5. Install the oil pan baffle and the bolts.
Tighten the oil pan baffle bolts to 12 N.m (106 lb in).

Intake Manifold Disassemble

1. Remove the nuts, the studs,and the accelerator control cable bracket.




2. Remove the throttle body attaching studs.




3. Remove the throttle body.
4. Remove the throttle body to upper intake manifold gasket.
5. Discard the throttle body to upper intake manifold gasket.




6. Remove the water outlet studs.
7. Remove the water outlet.
8. Remove the engine coolant thermostat.

Important: Note the position and direction of the exhaust gas recirculation (EGR) valve before removal. It is possible to improperly install the EGR valve 180 degrees from the original position.




9. Remove the exhaust gas recirculation (EGR) valve bolts.

Notice: The Linear EGR valve is an electrical component. DO NOT soak in any liquid cleaner or solvent because damage may result.




10. Remove the EGR valve and the EGR valve gasket from the lower intake manifold.
11. Discard the EGR valve gasket.




12. Remove the engine coolant temperature (ECT) sensor from the front of the lower intake manifold (if equipped).




13. Remove the studs and the ignition coil.




14. Remove the manifold absolute pressure (MAP) sensor.
15. Remove the MAP sensor seal from the MAP sensor.
16. Discard the MAP sensor seal.




17. Remove the fuel pipe bolt(4).
18. Remove the fuel pipe retainer nuts (1).
19. Remove the fuel pipe retainer (2).
20. Remove the fuel pipe (3).
21. Remove and discard the fuel seal retainers (5).
22. Remove and discard the fuel seals (6) (yellow O-rings).
23. Remove and discard the spacer rings (7) (flat washers).
24. Remove and discard the fuel seals (8) (black O-rings).




25. Remove the studs and the evaporative emission (EVAP) canister purge solenoid valve.
26. Remove the nut and the engine wiring harness bracket.




27. Remove the upper intake manifold attaching studs.
28. Remove the upper intake manifold.
29. Remove the upper intake manifold to lower intake manifold gasket.
30. Discard the upper intake manifold to lower intake manifold gasket.




31. Remove the TBI fuel meter body seal and discard.
32. Remove the 6 poppet nozzles from the lower intake manifold bores.
33. Remove the TBI fuel meter body.
34. Remove the bolt and the TBI fuel meter body bracket.

Intake Manifold Clean and Inspect

Caution: Wear safety glasses in order to avoid eye damage.




1. Clean the upper intake manifold in cleaning solvent.
2. Dry the upper intake manifold with compressed air.




3. Clean the lower intake manifold in cleaning solvent.
4. Dry the lower intake manifold with compressed air.




5. Inspect the upper intake manifold for the following:
- Cracks or other damage to the exterior
- Cracking or damage in the gasket grooves
- Loose or damaged bolt hole thread inserts
- Damage to the throttle body mounting surface
6. Inspect the lower intake manifold for the following:
- Cracks or damage
- Damage to the gasket sealing surfaces
- Damage to the threaded bolt holes
- Restricted exhaust gas recirculation (EGR) system passages
- Restricted cooling system passages

Intake Manifold Assemble




1. Install the TBI fuel meter body bracket and bolt.
Tighten the TBI fuel meter bracket bolt to 10 N.m (88 lb in).
2. Install the TBI fuel meter body into the TBI fuel meter body bracket.
3. Install the 6 poppet nozzles into the proper lower intake manifold bores.
4. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly seated and locked in the lower intake manifold bores.
5. Install a NEW TBI fuel meter body seal into the groove of the TBI fuel meter body.




6. Install a NEW upper intake manifold to lower intake manifold gasket into the groove of the upper intake manifold.
7. Install the upper intake manifold onto the lower intake manifold.
If reusing the fasteners, apply thread lock to the threads of the upper intake manifold attaching studs.
8. Install the upper intake manifold attaching studs.
1. Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in).
2. Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).




If reusing the fasteners,apply thread lock to the threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
9. Install the EVAP canister purge solenoid valve and studs.
Tighten the EVAP canister purge solenoid valve studs to 10 N.m (88 lb in).
10. Install the engine wiring harness bracket and nut.
Tighten the engine wiring harness bracket nuts to 12 N.m (106 lb in).




11. Install the NEW fuel seals (8) (black O-rings) into the TBI fuel meter body.
12. Install the NEW spacer rings (7) (flat washers) into the TBI fuel meter body.
13. Install the NEW fuel seals (6) (yellow O-rings) into the TBI fuel meter body.
14. Install the NEW fuel seal retainers (5) into the TBI fuel meter body.
15. Install the fuel pipe (3) into the TBI fuel meter body.
16. Install the fuel pipe retainer bracket (2) onto the fuel pipe.
17. Install the fuel pipe retainer bracket nuts (1).
18. If reusing the fastener, apply threadlock to the threads of the fuel pipe bolt.
19. Install the fuel pipe bolt (4).
1. Tighten the fuel pipe bracket nuts to 3 N.m (27 lb in).
2.Tighten the fuel pipe bolt to 6 N.m (53 lb in).




20. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP sensor.
21. Apply a small amount (1 drop) of clean engine oil to the MAP sensor seal.
22. Install the MAP sensor into the upper intake manifold




23. Install the ignition coil and studs.
Tighten the ignition coil studs to 12 N.m (106 lb in).




If reusing the engine coolant temperature (ECT) sensor (if equipped) apply sealant to the threads of the ECT sensor.
24. Install the ECT sensor into the front of the lower intake manifold (if equipped).
Tighten the ECT sensor to 20 N.m (15 lb ft).

Important: The EGR valve must be installed in the original orientation.




25. Install a NEW exhaust gas recirculation (EGR) valve gasket and the EGR valve.




26. Install the EGR valve bolts.
1. Tighten the EGR valve bolts on the first pass to 7 N.m (62 lb in).
2. Tighten the EGR valve bolts on the final pass to 30 N.m (22 lb ft).




27. Install the engine coolant thermostat.
28. Install the water outlet.
29. Install the water outlet studs.
Tighten the water outlet studs to 25 N.m (18 lb ft).




30. Install a NEW throttle body gasket into the groove in the upper intake manifold.
31. Install the throttle body onto the upper intake manifold.




If reusing the fasteners,apply thread lock to the threads of the throttle body attaching studs.
32. Install the throttle body attaching studs.
Tighten the throttle body attaching studs to 9 N.m (80 lb in).




33. Install the accelerator control cable bracket, the studs, and the nuts.
1. Tighten the accelerator control cable bracket stud to the intake manifold to 6 N.m (53 lb in).
2. Tighten the accelerator control cable bracket nuts to 12 N.m (106 lb in).
3. Tighten the accelerator control cable bracket stud to the throttle body to 12 N.m (106 lb in).

Exhaust Manifold Clean and Inspect

Caution: Wear safety glasses in order to avoid eye damage.




1. Clean the exhaust manifolds in cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the exhaust manifolds for the following:
- Damage to the gasket sealing surfaces
- Damage to the exhaust gas recirculation (EGR) pipe fitting (left manifold)
- Damage to the take down studs
- Restrictions within exhaust passages
- Broken or damaged exhaust manifold heat shields (if applicable)
- Broken or damaged exhaust manifold




4. Measure the alignment or surface flatness of the exhaust manifold flanges using a straight edge and a feeler gauge. Refer to Engine; Specifications; Mechanical.
If the surface flatness is not within the specifications, the exhaust manifold is warped and must be replaced.

Water Pump Clean and Inspect

Caution: Wear safety glasses in order to avoid eye damage.




1. Remove the old gasket material from the water pump sealing surfaces.
2. Clean all excess dirt and debris from the water pump housing.
3. Inspect the water pump for the following:
- Gasket sealing surfaces for excessive scratches or gouging
- Restrictions within the internal coolant passages
- Excessive side-to-side play in the pulley shaft
- Leakage at the water inlet pipe or housing rear cover gasket
- Leakage at the water pump vent hole
A stain around the vent hole is acceptable. If leakage occurred (dripping) with the engine operating and the cooling system pressurized, then replace the water pump.
- Damaged bolt hole threads