Intake Manifold: Service and Repair

1. Disconnect and plug fuel supply and return lines. Relieve fuel system pressure before disconnecting fuel hoses.
2. Disconnect electrical connectors and vacuum hoses as needed, and secure wiring and hoses aside.
3. Disconnect accelerator, cruise control and downshift cables from TBI unit and brackets.
4. Rotate belt tensioner counterclockwise to release tension, and remove drive belt.
5. Remove AIR pump pulley, air management valve adapter and AIR pump.
6. Disconnect upper radiator and heater hoses, and remove bolts securing accessory mounting brackets to manifold.
7. Disconnect spark plug wires, remove distributor cap, and lay cap and wire assembly aside.
8. Mark position of distributor rotor and remove distributor.
9. Remove intake cover and TBI assembly.

Fig. 7 Intake manifold installation.:

10. Remove intake manifold bolts and manifold.
11. Ensure surfaces are clean and dry, then apply 3/16 bead of RTV sealer on each block ridge and apply suitable sealer around water outlets, install gaskets and secure gasket position by extending bead of sealer approximately 1/2 inch onto gasket ends.
12. Install manifold and retaining bolts, ensuring areas between case ridges and manifold are completely sealed.
13. Torque manifold bolts in sequence shown in Fig. 7, to 35 Ft. Lbs.
14. Reverse remaining procedure to complete installation.