Intake Manifold Replacement Lower

1. Mark the relationship of the distributor housing and rotor for proper reassembly.
2. Remove the distributor. Refer to Distributor Replacement in Engine Electrical.
3. Remove the upper radiator hose at the thermostat housing. Refer to Radiator Hose Replacement in Engine Cooling.
4. Remove the heater hose at the lower intake manifold. Refer to Heater Hose Replacement in Heater, Ventilation, and Air Conditioning.
5. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
6. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
7. Remove the coolant bypass hose. Refer to Bypass Hose Replacement in Engine Cooling.
8. Remove the fuel supply and return lines at the rear of the lower intake manifold. Refer to Fuel Hose and Pipes in Engine Controls.
9. Remove the wiring harness and brackets.
10. Remove the throttle cable and bracket.
11. Remove the cruise control cable (if equipped).
12. Remove the transmission oil level indicator tube, (if equipped). Refer to Transmission.
13. Remove the EGR inlet tube, clamp, and bolt.
14. Remove the PCV valve and vacuum hoses.
15. Remove the air conditioning compressor. Refer to Compressor in Heater, Ventilation, and Air Conditioning.

•	Loosen the A/C compressor mounting bracket and slide forward, do not remove.

•	Lay the A/C compressor out of the way. Do not kink the air conditioning lines.

16. Remove the power brake vacuum tube.
17. Remove the generator rear bracket bolt, (if needed).



18. Remove the lower intake manifold.
19. Remove the old pieces of gasket from the gasket surfaces.
20. Remove excessive carbon buildup from inside the exhaust passages.
21. Remove the scale and deposits from the coolant passages.
22. Clean the EGR passage of excessive carbon deposits.
23. Inspect the manifold for cracks, broken flanges, and gasket surface damage.

1. Install the gaskets to the cylinder head with the port blocking plates facing the rear of the engine and This Side Up stamping facing up.



2. Install RTV to the front and the rear sealing surfaces on the block. Apply a 5 mm (3/16 in) bead of RTV GM P/N 1052366 or equivalent to the front and the rear of the block. Extend the bead 13 mm (1/2 in) up each cylinder head to seal and retain the gaskets.



3. Install the lower intake manifold to the engine. Apply sealer, GM P/N 1052080 or equivalent, to the lower intake manifold bolts.



4. Install the lower intake manifold bolts. Tighten the bolts in three steps:

Tighten

1. Tighten the bolts on the first sequence to 8 N·m (71 lb in).
2. Tighten the bolts on the second sequence to 12 N·m (106 lb in).
3. Tighten the bolts on the final sequence to 15 N·m (11 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the wiring harness connectors and brackets.
6. Install the upper radiator hose at the thermostat housing. Refer to Radiator Hose Replacement in Engine Cooling.
7. Install the heater hose at the lower intake manifold. Refer to Heater Hose Replacement in Engine Cooling.
8. Install the coolant bypass hose. Refer to Bypass Hose Replacement in Heater, Ventilation, and Air Conditioning.
9. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
10. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement .
11. Install the fuel supply and return lines at the rear of the lower intake manifold. Refer to Fuel Hose and Pipes in Engine Controls.
12. Install the wiring harness and brackets.
13. Install the cruise control cable (if equipped).
14. Install the throttle cable and bracket. Refer to Accelerator Controls (Accelerator Control Cable) in Engine Controls.
15. Install the transmission oil level indicator tube. Refer to Transmission.
16. Install the EGR inlet tube, clamp, and bolt.
17. Install the PCV valve and vacuum hoses.
18. Install the power brake vacuum tube.
19. Install the generator and the bracket bolt, (if needed).
20. Install the air conditioning compressor and bracket. Refer to Heater, Ventilation, and Air Conditioning.
21. Install the distributor. Note the relationship of the distributor housing and rotor made at disassembly. Refer to Distributor Replacement in Engine Electrical.

Intake Manifold Replacement Upper

1. Disconnect the battery negative cable assembly from the battery negative terminal. Refer to

   Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

   Battery Disconnect Caution in General Information.
2. Remove the air cleaner assembly. Refer to Air Cleaner (Assembly) in Engine Controls.



3. Remove the wiring harness connectors and the brackets and move aside.
4. Remove the throttle cable and the bracket from the upper intake manifold.
5. Remove the cruise control cable, (if equipped).
6. Remove the fuel lines from the intake to the rear of the block. Refer to Fuel Hose and Pipes Fuel Hose and Pipes (Engine Fuel Pipes) in Engine Controls.
7. Remove the ignition coil and the bracket. Refer to Ignition Coil Replacement in Engine Electrical.
8. Remove the upper intake manifold. Refer to Intake Manifold Removal

1. Install the upper intake manifold gasket.
2. Install the upper intake manifold. Use care not to pinch the injector lines between the upper and lower intake manifolds.
3. Install the upper intake manifold bolts. Note the marks made at disassembly for proper stud location. Install the two corner studs first in order to help align the two halves.
4. Tighten the bolts in two steps:

Tighten

1. Tighten the bolts on the first sequence to 5 N·m (45 lb in).
2. Tighten the bolts on the final sequence to 10 N·m (83 lb in).
5. Install the purge solenoid and bracket. Refer to Evaporative Emission Vacuum Switch EVAP Vacuum Switch in Engine Controls.
6. Install the ignition coil and bracket. Refer to Ignition Coil Replacement in Engine Electrical.
7. Install the PCV hose at the upper intake manifold.
8. Install the fuel lines from the intake at the rear of the block. Refer to Fuel Hose and Pipes Fuel Hose and Pipes (Engine Fuel Pipes) in Engine Controls.
9. Install the cruise control cable (if equipped).
10. Install the throttle cable and bracket from the upper intake manifold. Refer to Accelerator Controls (Accelerator Control Cable) In Engine Controls.
11. Install the wiring harness connectors and brackets.
12. Install the air cleaner assembly. Refer to Air Cleaner (Assembly) in Engine Controls.
13. Connect the battery negative cable assembly to the battery negative terminal.

Tighten
Tighten the bolt to 15 N·m (11 lb ft).