Intake Manifold: Service and Repair

Fig. 2 Fuel Rail & Plenum Replacement:

Fig. 3 Intake Manifold Replacement & Bolt Tightening Sequence:

1. Disconnect battery ground cable, remove air cleaner and drain cooling system.
2. Relieve fuel system pressure as described under MAINTENANCE PROCEDURE/RELIEVING FUEL SYSTEM PRESSURE
3. Disconnect air inlet duct, electrical connectors, coolant hoses and vacuum hoses from throttle body, noting position for installation.
4. Disconnect accelerator, cruise control and transmission cables, as equipped.
5. Remove throttle body retaining bolts and the throttle body.
6. Remove EGR pipe retaining bolts and throttle cable bracket.
7. Remove bolts securing plenum to manifold and the plenum, Fig. 2.
8. Disconnect fuel lines from fuel rail and remove cold start valve.
9. Disconnect vacuum hose from pressure regulator and remove fuel rail retaining bolts.
10. Disconnect injector harness connectors and remove fuel rail assembly, Fig. 2.
11. Disconnect high tension leads from spark plugs and disconnect wiring from coil.
12. Remove distributor cap and plug wire assembly.
13. Rotate crankshaft until No. 1 cylinder is at TDC on compression stroke, mark position of distributor rotor and remove distributor.
14. Remove air injection hose, if equipped, disconnect canister hoses and remove pipe bracket from front of left valve cover.
15. Remove left valve cover and air management bracket, then remove right valve cover.
16. Disconnect upper radiator and heater hoses from manifold.
17. Disconnect coolant switches and remove manifold retaining bolts.
18. Remove manifold and thoroughly clean old gasket and sealer from mating surfaces.
19. Ensure surfaces are clean and dry, then apply 3/16 bead of RTV sealer on each block ridge, install gaskets and secure gasket position by extending bead of sealer approximately 1/4 inch onto gasket ends. New gaskets must be cut to fit behind push rods. When installing gaskets, note left and right side markings.
20. Install manifold and retaining bolts, ensuring areas between case ridges and manifold are completely sealed.
21. Torque manifold bolts to specifications in sequence shown in Fig. 3, then reverse remaining procedure to complete installation.