Intake Manifold: Service and Repair

REMOVAL
1. Disconnect battery.
2. Remove air cleaner.
3. Drain coolant.
4. Remove the following PFI sub-assemblies.
^ Plenum
^ Fuel Rail
^ Runner
5. Disconnect spark plug wires at spark plugs.
6. Disconnect wires at coil.
7. Remove distributor cap and spark plug wires.
8. Mark distributor position and remove hold down bracket.
9. Remove distributor.
10. Remove air management hose, manual transmission only.
11. Disconnect emission canister hoses. Remove pipe bracket (front left valve cover).
12. Remove left valve cover. Service and Repair
13. Remove air management bracket, manual transmission only.
14. Remove right valve cover. Service and Repair
15. Remove upper radiator hose.
16. Disconnect heater hose.
17. Disconnect coolant switches.
18. Remove manifold bolts.
19. Remove manifold. Discard manifold gaskets and remove loose RTV from front and rear ridges of cylinder case.

INSTALLATION

NOTE: When installing intake gaskets, notice that the gaskets are marked Right Side and Left Side (carbureted only). Use them only as indicated to maintain designed efficiency of this engine.

1. Make sure that no oil or water is present on surface when new RTV is applied. Place a 5 mm diameter (3/16") bead of RTV, #1052917 or equivalent, on each ridge.
2. Install new intake gaskets on cylinder heads. Hold in place by extending ridge RTV bead up 6mm onto the gasket ends. The new intake gaskets will have to be cut, where indicated, to install behind push rods. Cut only those areas that are necessary.
3. Install intake manifold on engine. Make sure areas between case ridges and intake are completely sealed.

Intake Manifold:

4. Install manifold retaining bolts and nuts and torque in the sequence shown.
5. Install heater and radiator hose to manifold.
6. Install rocker covers. Service and Repair
7. Connect coolant switches.
8. Install air management bracket.
9. Install pipe bracket (front left rocker cover).
10. Install distributor, distributor cap and retaining nut. Do not tighten.

Fig. 5 Manifold plenum & fuel rail installation. 1985---88 V6-173:

11. Install PFI sub-assemblies removed.
12. Connect necessary wires and hoses.
13. Fill cooling system with the proper mixture of ethylene glycol anti-freeze and water. Do not install radiator cap.
14. Start engine, set initial timing. After set, torque distributor hold down clamp bolt to 34 Nm (25 lb. ft.). Recheck timing after torquing bolt.
15. Let engine run until radiator upper hose becomes hot (thermostat open).
16. With engine idling, add coolant to radiator, if necessary, until level reaches bottom of filler neck.
17. Install radiator cap, making sure arrows on cap line up with overflow tube.