Intake Manifold

REMOVE OR DISCONNECT
1. Battery ground cable.
2. Accelerator and T.V. cable bracket at the plenum.
3. Throttle body at plenum.
4. EGR valve at plenum.
5. Plenum.
6. Fuel inlet and return pipes at fuel rail.
7. Serpentine belt..
8. Power steering pump and lay aside.
9. Generator and lay aside.
10. Loosen generator bracket.
11. Idle air vacuum hose at the throttle body.
12. Wires at injectors.
13. Fuel rail.
14. Breather tube.
15. Both Valve covers.
16. Drain cooling system.
17. Radiator hose at thermostat outlet.
18. Wires at coolant sensor and oil sending switch.
19. Coolant sensor.
20. Bypass hose at fill neck and head.
21. Heater inlet pipe at manifold.
22. Intake manifold bolts.
23. Intake manifold.
24. Loosen rocker arms.
25. Push rods.

CLEAN
^ Gasket material
^ Loose RTV from front and rear ridges of cylinder block
^ Sealing surfaces with degreaser

INSTALL OR CONNECT
1. Place a 3mm diameter (3/16") bead of GM 1052917. RTV sealer or equivalent on each ridge.
2. Intake gasket.
3. Push rods.
4. Rocker arms
Tighten
^ Nuts to 20-27 Nm (14-20 ft. lbs.).
5. Intake manifold on engine
6. Manifold bolts and nuts
Tighten
^ Per figure
7. Heater inlet pipe.
8. Coolant sensor.
9. Wires at coolant sensor and oil.
10. Sending unit.
11. Radiator hose at the thermostat outlet.
12. Fill cooling system.
13. Rocker arm cover as previously outlined.
Tighten
^ Bolts to 8-12 Nm (6-9)
14. Breather tube.
15. Fuel rail.
16. Wires at injectors.
17. Idle air vacuum hose at throttle body.
18. Generator bracket.
Tighten
^ Bolts to 40-54 Nm (30-40 ft. lb.)
19. Generator.
Tighten
^ Bolts to 27-41 Nm (ft. lb.)
20. P/S pump.
Tighten
^ Bolts to 34-41 Nm (25-30 ft. lb.)
^ Nuts to 50-56 Nm (36-41 ft. lb.)
21. Serpentine belt.
22. Fuel inlet and return pipes at fuel rail.
23. Plenum.
24. EGR valve.
25. Throttle body at the plenum.
26. Accelerator and T.V. cable bracket a plenum.
27. Connect battery.

INSPECT
^ Coolant level
^ For fluid leaks