Intake Manifold: Service and Repair

Fig. 8 Intake manifold installation. V6-173 exc. MFI:

V6-173
Exc. EFI
1. Disconnect battery ground cable, drain cooling system and remove air cleaner.
2. Remove front engine strut, then the strut bracket from the cylinder head, if applicable.
3. Disconnect vacuum hoses and fuel lines as needed.
4. Disconnect wires from spark plugs and retainers on valve covers.
5. Disconnect electrical connectors from carburetor and manifold, as needed, then remove harness from clamps on valve cover.
6. Remove accelerator linkage and return springs from carburetor, and disconnect transmission detent cable, if equipped.
7. On models with cruise control, remove diaphragm actuator bracket.
8. On all models, remove both valve covers.
9. Remove AIR pump and bracket.
10. On all models, remove distributor cap and plug wire assembly.
11. Mark position of distributor rotor for installation, then remove distributor.
12. Disconnect heater, radiator and brake booster hoses from manifold.
13. On all models, remove manifold retaining bolts, manifold and gaskets.
14. Install replacement gaskets on cylinder heads, cutting gaskets only where needed to clear push rods. Hold gaskets in position by extending sealer bead approximately 1/4 inch past end of block end rails.
15. Install manifold and torque bolts in sequence as shown in Fig. 8.
16. Reverse remaining procedure to complete installation.

Fig. 9 Typical intake manifold installation. V6-173 w/MFI:

With EFI
1. Disconnect battery ground cable, drain cooling system and remove air duct between throttle body and air cleaner.
2. Disconnect vacuum hoses from plenum.
3. Remove bolts securing EGR pipe and throttle body to plenum.
4. Remove throttle cable bracket bolts and bracket.
5. Remove 10 plenum retaining bolts and the plenum, Fig. 9.
6. Connect gauge J-34730-1 or equivalent to fuel pressure regulator and bleed off pressurized fuel into a suitable container.
7. Disconnect cold start valve and fuel lines from fuel rail assembly.
8. Disconnect vacuum hose from regulator and electrical connectors from injectors.
9. Remove fuel rail retaining bolts and the fuel rail.
10. Remove intake manifold.
11. Reverse procedure to install, using new gaskets and injector seals.