Intake Manifold: Service and Repair

LOWER

Remove or Disconnect
1. Negative battery cable
2. Air cleaner assembly
3. Drain engine coolant as necessary
4. Upper intake manifold and fuel rails
5. Coolant reservoir
6. Accessory drive belt
7. P/S line brace on R.H. cylinder head
8. P/S and tensioner bracket assembly and reposition toward front of engine
9. Generator with bracket and idler pulley
10. C/C (with bracket) and cables and reposition
11. Wire connections and reposition
^ Distributor
^ Oil pressure switches
^ Coolant temperature sensor
^ Ground Wires

12. Upper radiator hose and two heater hose connections
13. Spark plug wire protectors and reposition cap
14. Mark distributor rotor position and remove distributor
Important
^ Do not crank or in any other way rotate crankshaft with the distributor removed.
^ Carefully bleed fuel pressure at fuel line test port (schraeder valve) using a suitable tool and container or rag to catch fuel.

15. Valve covers
16. Rocker arms and push rods
Important
^ Push rods should be marked or retained in sequence so that they may be reinstalled in their original positions

17. Intake manifold bolts
18. Lower intake manifold
19. Gaskets, seals and discard
Clean
1. Sealing surfaces of:
^ Intake manifold
^ Cylinder head
^ Cylinder block

Install or Connect
1. New end seals
2. RTV 1052915 to four corners where end seals will meet side gaskets
3. New intake to cylinder head gaskets. Gaskets for port fuel injection engine are the same for right and left sides. Gaskets are also specific to this engine.
4. RTV 1052915 to four corners of end seals
5. Lower Intake manifold
6. Intake manifold bolts
Tighten
^ Intake manifold bolts in sequence

7. Push rods and rocker arm assembly
8. Valve covers
9. Distributor in original position
10. Distributor cap and wire protectors
11. Upper radiator hose and 2 heater hoses
12. Wire connectors
^ Distributor
^ Oil Pressure switch
^ Coolant sensor
^ Ground wires

13. C/C assembly cable
14. Generator with bracket and idler pulley
15. P/S pump and tensioner assembly
16. P/S line brace to R.H. cylinder head
17. Accessory drive belt
18. Coolant reservoir
19. Upper intake manifold and fuel rails
20. Fill engine coolant
21. Negative battery cable
22. Start engine and set base timing