Installation

1. If the intake manifold assembly was disassembled, install the temperature sending unit (threads coated with electrical conductive sealer). Position the thermostat in the coolant outlet housing. Coat the thermostat gasket with Perfect Seal Sealing Compound or equivalent and position it on the coolant outlet housing. Install the coolant outlet housing. Connect all vacuum hoses.

Intake Manifold RTV Sealer Application:

2. Clean the mating surfaces of the intake manifold, cylinder heads and cylinder block. Use a solvent such as lacquer thinner, chlorothane or equivalent. Apply a 1/8 inch (3.2mm) bead of Silicone Rubber Sealer or equivalent, at the points shown.
3 Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Ensure the holes in the gaskets are aligned with the holes in the cylinder heads. Apply a 1/16 inch (1.6mm) bead of sealer to the outer end of each intake manifold seal for the full width of the seal (four places). NOTE: This sealer sets up in 15 minutes, so it is important that assembly be completed promptly. Do not drip any sealer into the engine valley.
4. Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads. After the intake manifold is in place, run a finger around the seal area to ensure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals.

Lower Intake Manifold Assembly:

Upper Intake Manifold:

5. Ensure the holes in the manifold gaskets and manifold are in alignment. Remove guide pins. Install the intake manifold attaching bolts and nuts. Tighten the intake manifold bolts in sequence to 23-25 ft lbs (31-34 Nm).
6. Install the water pump bypass hose on the coolant outlet housing. Slide the clamp into position and tighten the clamp. Install hoses to heater tubes and tighten clamps.
7. Connect the radiator upper hose. Connect the heater hose at the intake manifold.
8. Install the fuel lines.
9. Rotate the crankshaft until the No. 1 piston is on TDC at the end of the compression stroke. Align the correct initial timing mark on the damper with the pointer. Position the distributor in the block with the rotor at the No. 1 firing position and the armature tooth centered on the stator (pick-up) coil. Install the hold-down clamp.
10. Install the distributor cap. Position the spark plug wires in the harness brackets on the valve rocker arm cover attaching stud and connect the wires to the spark plugs.
11. Install upper intake manifold.
12. Install EGR spacer and throttle body.
13. Connect the crankcase vent tube.
14. Connect the accelerator cable and accelerator cable bracket. Connect TV cable and speed control, if equipped, to the throttle body. Connect the transmission vacuum line (except on AOD transmissions). Connect all electrical connections disconnected during removal. Connect any vacuum lines that were disconnected from the intake manifold during removal. Connect coolant hoses to EGR spacer.
15. Fill and bleed the cooling system.
16. Start the engine. Check and adjust the ignition timing.
17. Operate the engine at fast idle and check all hose connections and gaskets for leaks. When engine temperatures have stabilized, adjust the engine idle speed. Tighten intake manifold bolts to 23-25 ft. lbs. (31-34 Nm).
18. Install the air intake duct assembly and crankcase vent hose.