AutoZone 1995 Toyota Truck 4 Runner 2WD 3.0L EFI 6cyl | Repair Guides | Engine & Engine Overhaul | Engine Mechanical | Lower Intake Manifold | AutoZone.com

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    GM Full-Size Trucks 1988-1998 Repair Information

    Lower Intake Manifold

    Print

    For the 4.8L engine, please refer to the Combination Manifold procedure.

    REMOVAL & INSTALLATION



    4.3L Engines
    1988-95 MODELS

    See Figures 1, 2 and 3

    1. Disconnect the negative battery cable. Drain the cooling system.
    2.  
    3. Remove the air cleaner assembly.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 1: Intake manifold installation-4.3L engines



    Click image to see an enlarged view

    Fig. Fig. 2: Intake manifold bolt tightening sequence-1988-91 4.3L engines



    Click image to see an enlarged view

    Fig. Fig. 3: Intake manifold bolt tightening sequence-1992-95 4.3L engines

    Mark the relationship of the distributor and rotor for proper reassembly

    1. Remove the distributor.
    2.  
    3. Disconnect the accelerator and cruise control cables with their brackets.
    4.  
    5. Remove the rear air conditioner compressor bracket, the alternator bracket and the idler pulley bracket at the manifold.
    6.  
    7. Disconnect all electrical connections and vacuum lines from the manifold. Remove the EGR valve if necessary.
    8.  
    9. Disconnect the fuel line at the intake manifold.
    10.  
    11. Remove the heater pipe.
    12.  
    13. Disconnect the upper radiator hose and pull it off.
    14.  
    15. Tag and disconnect the power brake vacuum pipe and the EGR vacuum line.
    16.  
    17. Tag and disconnect the coil wires and if necessary remove the coil.
    18.  
    19. Remove the sensors and bracket on the right side. Disconnect the wiring harness on the right side and position it out of the way.
    20.  

    Mark the location of the intake manifold studs for proper reassembly

    1. Remove the intake manifold bolts. Remove the manifold and the gaskets. Remember to reinstall the O-ring between the intake manifold and timing chain cover during assembly, if so equipped.
    2.  

    To install:

    Before installing the intake manifold, be sure that the gasket surfaces are thoroughly clean.

    1. Use plastic gasket retainers to prevent the manifold gasket from slipping out of place, if so equipped. Coat the front and rear sealing surfaces with a 0.19 in. (5mm) bead of RTV sealant. Extend the bead approximately 1 / 2 in. (13mm) down each head to help retain the gaskets.
    2.  
    3. Install the manifold and the gaskets. Remember to reinstall the O-ring between the intake manifold and timing chain cover, if so equipped.
    4.  
    5. Install the intake manifold bolts and tighten them to 35 ft. lbs. (48 Nm) in the sequence shown.
    6.  
    7. Connect the coil wires. Install the sensors and bracket on the right side. Connect the wiring harness.
    8.  
    9. Connect the power brake vacuum pipe and the EGR vacuum line.
    10.  
    11. Connect the upper radiator hose.
    12.  
    13. Install the heater pipe.
    14.  
    15. Connect the fuel line(s).
    16.  
    17. Connect all electrical connections and vacuum lines at the manifold. Install the EGR valve.
    18.  
    19. Install the rear air conditioner compressor bracket, the alternator bracket and the idler pulley bracket at the manifold.
    20.  
    21. Connect the accelerator and cruise control cables with their brackets.
    22.  
    23. Install the distributor.
    24.  
    25. Install the air cleaner assembly.
    26.  
    27. Fill the cooling system.
    28.  

    1996-98 MODELS

    See Figure 4



    Click image to see an enlarged view

    Fig. Fig. 4: Intake manifold bolt tightening sequence-1996-98 4.3L engines

    1. Drain and recycle the engine coolant.
    2.  
    3. Remove the upper intake manifold using the recommended procedure outlined in this section.
    4.  
    5. Remove the distributor.
    6.  
    7. Disconnect the upper radiator hose from the thermostat housing.
    8.  
    9. Disconnect the heater hose from the lower intake manifold.
    10.  
    11. Remove the coolant by-pass hose.
    12.  
    13. Remove the EGR valve.
    14.  
    15. Disconnect the fuel pressure and return lines from the lower intake manifold.
    16.  
    17. Disconnect the wiring harnesses and brackets from the lower manifold.
    18.  
    19. Disconnect the throttle cable, the cruise control cable (if equipped) and the bracket from the manifold.
    20.  
    21. Remove the transmission oil level indicator and tube, if equipped.
    22.  
    23. Remove the EGR tube, clamp and bolt.
    24.  
    25. Remove the PCV valve and vacuum hoses.
    26.  
    27. Remove the A/C compressor and bracket, but do NOT disconnect the lines. Move the compressor out of the way. Take care not to kink the A/C lines.
    28.  
    29. Loosen the compressor mounting bracket and slide it forward, but do NOT remove it.
    30.  
    31. Remove the alternator bracket bolt located next to the thermostat, if necessary.
    32.  
    33. Remove the lower intake manifold bolts.
    34.  
    35. Remove the lower intake manifold.
    36.  

    To install:
    1. Clean all gasket surfaces completely.
    2.  
    3. Install the intake manifold gaskets with the port blocking plates facing the rear of the engine. Factory gaskets should have the words "This Side Up" visible.
    4.  
    5. Apply gasket sealer to the front and rear sealing surfaces of the engine block.
    6.  
    7. Apply a 0.197 inch (5mm) bead of RTV sealer to the front and rear of the block. Extend the sealer approximately 1 / 2 -inch (13mm) onto the heads.
    8.  
    9. Install the lower intake manifold.
    10.  
    11. Apply sealer to the lower intake manifold bolts prior to installation.
    12.  
    13. Install the bolts and tighten in sequence and in 3 steps as follows:
      1. First step to 26 inch lbs. (3 Nm).
      2.  
      3. Second step to 106 inch lbs. (12 Nm).
      4.  
      5. Final step to 11 ft. lbs. (15 Nm).
      6.  

    14.  
    15. If removed, install the alternator bracket bolt.
    16.  
    17. Install the coolant by-pass hose.
    18.  
    19. Install the EGR valve.
    20.  
    21. Connect the upper radiator hose to the thermostat housing.
    22.  
    23. Connect the heater hose to the lower intake manifold.
    24.  
    25. Connect the fuel pressure and return lines to the lower intake manifold.
    26.  
    27. Connect the wiring harnesses and brackets to the lower manifold.
    28.  
    29. Install the throttle cable bracket, then attach the throttle cable and the cruise control cable (if equipped).
    30.  
    31. Install the transmission oil level indicator and tube, if equipped.
    32.  
    33. Install the EGR tube, clamp and bolt.
    34.  
    35. Install the PCV valve and hose.
    36.  
    37. Install the A/C compressor and bracket.
    38.  
    39. Install the distributor.
    40.  
    41. Install the upper intake manifold.
    42.  
    43. Fill the cooling system.
    44.  
    45. Connect the negative battery cable.
    46.  
    47. Start the vehicle and check the ignition timing (not adjustable).
    48.  
    49. Verify no oil, coolant, vacuum or fuel leaks.
    50.  

    5.0L and 5.7L Engines

    1988-95 MODELS

    See Figures 5, 6, 7, 8 and 9

    1. Disconnect the negative battery cable. Drain the cooling system.
    2.  
    3. Remove the air cleaner assembly.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 5: Intake manifold-5.0L and 5.7L engines



    Click image to see an enlarged view

    Fig. Fig. 6: Intake manifold bolt tightening sequence-1988-95 5.0L and 5.7L engines

    1. Remove the upper radiator hose from the thermostat housing.
    2.  
    3. Disconnect the heater pipe at the rear of the manifold.
    4.  
    5. Disconnect the rear alternator brace at the manifold.
    6.  
    7. Disengage all electrical connections and vacuum lines from the manifold. Remove the EGR valve if necessary.
    8.  

    Mark the relationship of the distributor and rotor for proper reassembly

    1. Remove the distributor.
    2.  
    3. Disconnect the fuel line at the intake manifold.
    4.  
    5. Remove the accelerator and cruise control linkage.
    6.  
    7. Remove the air conditioner compressor rear bracket.
    8.  
    9. Remove the brake booster vacuum pipe and then disconnect the coil wires.
    10.  
    11. Remove the emission control sensors and their bracket from the right side.
    12.  
    13. Remove the fuel line bracket at the rear of the manifold and position the fuel lines out of the way.
    14.  
    15. Remove the bracket behind the idler pulley.
    16.  
    17. Remove the carburetor or TBI unit if necessary. Refer to Fuel Systems for this procedure.
    18.  

    Mark the location of the intake manifold studs for proper reassembly

    1. Remove the intake manifold bolts. Remove the manifold and the gaskets. Remember to reinstall the O-ring between the intake manifold and timing chain cover during assembly, if so equipped.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 7: Remove the intake manifold retaining bolts



    Click image to see an enlarged view

    Fig. Fig. 8: Remove the intake manifold



    Click image to see an enlarged view

    Fig. Fig. 9: Using a scraper, clean the intake manifold gasket mating surfaces

    To install:

    Before installing the intake manifold, be sure that the gasket surfaces are thoroughly clean.

    1. Use plastic gasket retainers to prevent the manifold gasket from slipping out of place, if so equipped. Place a 3 / 16 in. (5mm) bead of RTV type silicone sealer on the front and rear ridges of the cylinder block-to-manifold mating surfaces. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the manifold side gaskets.
    2.  
    3. Install the manifold and the gaskets. Remember to reinstall the O-ring between the intake manifold and timing chain cover, if so equipped.
    4.  
    5. Install the intake manifold bolts and tighten in the proper sequence. Tighten to 35 ft. lbs. (48Nm).
    6.  
    7. Install the carburetor or TBI unit if removed. Refer to Fuel Systems for this procedure.
    8.  
    9. Install the bracket behind the idler pulley.
    10.  
    11. Install the fuel line bracket at the rear of the manifold.
    12.  
    13. Install the emission control sensors and their bracket on the right side.
    14.  
    15. Install the brake booster vacuum pipe and then connect the coil wires.
    16.  
    17. Install the air conditioner compressor rear bracket.
    18.  
    19. Install the accelerator and cruise control linkage.
    20.  
    21. Install the fuel line and bracket.
    22.  
    23. Install the distributor.
    24.  
    25. Engage all electrical connections and vacuum lines at the manifold. Install the EGR valve.
    26.  
    27. Connect the rear alternator brace at the manifold.
    28.  
    29. Connect the heater pipe to the rear of the manifold.
    30.  
    31. Install the upper radiator hose.
    32.  
    33. Install the air cleaner assembly.
    34.  
    35. Connect the negative battery cable. Fill the cooling system.
    36.  

    1996-98 MODELS

    See Figure 10



    Click image to see an enlarged view

    Fig. Fig. 10: Intake manifold bolt tightening sequence-1996-98 5.0L and 5.7L engines

    1. Remove the upper intake manifold using the recommended procedure outlined in this section.
    2.  
    3. Remove the distributor.
    4.  
    5. Disconnect the upper radiator hose from the thermostat housing.
    6.  
    7. Disconnect the heater hose from the lower intake manifold.
    8.  
    9. Remove the coolant by-pass hose.
    10.  
    11. Remove the EGR valve.
    12.  
    13. Disconnect the fuel pressure and return lines from the lower intake manifold.
    14.  
    15. Disconnect the wiring harnesses and brackets from the lower manifold.
    16.  
    17. Disconnect the throttle cable, the cruise control cable (if equipped) and the bracket from the manifold.
    18.  
    19. If necessary, remove the left side valve cover.
    20.  
    21. Remove the transmission oil level indicator and tube, if equipped.
    22.  
    23. Remove the EGR tube, clamp and bolt.
    24.  
    25. Remove the PCV valve and vacuum hoses.
    26.  
    27. Remove the A/C compressor and bracket, but do NOT disconnect the lines. Move the compressor out of the way. Take care not to kink the A/C lines.
    28.  
    29. Loosen the compressor mounting bracket and slide it forward, but do NOT remove it.
    30.  
    31. Remove the power brake vacuum tube.
    32.  
    33. If necessary, remove the alternator rear bracket bolt.
    34.  
    35. Remove the lower intake manifold bolts.
    36.  
    37. Remove the lower intake manifold.
    38.  

    To install:
    1. Clean all gasket surfaces completely.
    2.  
    3. Install the intake manifold gaskets with the port blocking plates facing the rear. Factory gaskets should have the words "This Side Up" visible.
    4.  
    5. Apply gasket sealer to the front and rear sealing surfaces of the engine block.
    6.  
    7. Apply a 0.197 inch (5mm) bead of RTV sealer to the front and rear of the block. Extend the sealer approximately 1 / 2 -inch (13mm) onto the heads.
    8.  
    9. Install the lower intake manifold.
    10.  
    11. Apply sealer to the lower intake manifold bolts prior to installation.
    12.  
    13. Install the bolts and tighten in sequence and in 3 steps as follows:
      1. First step to 71 inch lbs. (8 Nm).
      2.  
      3. Second step to 106 inch lbs. (12 Nm).
      4.  
      5. Final step to 11 ft. lbs. (15 Nm).
      6.  

    14.  
    15. Connect the wiring harnesses and brackets to the lower manifold.
    16.  
    17. Install the power brake vacuum tube.
    18.  
    19. Install the PCV valve and hose.
    20.  
    21. Install the EGR tube, clamp and bolt.
    22.  
    23. Install the transmission oil level indicator and tube, if equipped.
    24.  
    25. If removed, install the left side valve cover.
    26.  
    27. Connect the fuel pressure and return lines to the lower intake manifold.
    28.  
    29. Connect the wiring harnesses and brackets to the lower manifold.
    30.  
    31. Install the throttle cable bracket, then attach the throttle cable and the cruise control cable (if equipped).
    32.  
    33. Install the EGR valve.
    34.  
    35. Install the coolant by-pass hose.
    36.  
    37. Connect the heater hose to the lower intake manifold.
    38.  
    39. Connect the upper radiator hose to the thermostat housing.
    40.  
    41. If removed, install the alternator bracket bolt.
    42.  
    43. Install the A/C compressor and bracket.
    44.  
    45. Install the distributor.
    46.  
    47. Connect the negative battery cable.
    48.  
    49. Refill the cooling system.
    50.  
    51. Start the vehicle and check the ignition timing (not adjustable).
    52.  
    53. Verify no oil, coolant, vacuum or fuel leaks.
    54.  

    Diesel Engines

    1988-95 models

    See Figure 11

    1. Disconnect both batteries.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 11: Intake manifold bolt tightening sequence-1988-95 diesel engines

    1. Remove the air cleaner assembly.
    2.  
    3. Remove the alternator rear bracket.
    4.  
    5. Remove the EPR/EGR boost solenoids and bracket.
    6.  
    7. Tag and disconnect the Crankcase Depression Regulator (CDR) hose.
    8.  
    9. Tag and disconnect the EGR and crankcase vent hoses.
    10.  
    11. Remove the intake manifold bolts. The injection line clips are retained by these bolts.
    12.  
    13. Remove the intake manifold.
    14.  

    If the engine is to be further serviced with the manifold removed, install protective covers over the intake ports.

    To install:
    1. Clean the manifold gasket surfaces on the cylinder heads and install new gaskets before installing the manifold.
    2.  

    The gaskets have an opening for the EGR valve on light duty installations. An insert covers this opening on heavy duty installations.

    1. Install the manifold. Tighten the bolts in the sequence illustrated to 32 ft. lbs. (42 Nm).
    2.  
    3. Install the ground straps and fuel line brackets.
    4.  
    5. Engage any electrical connections and vacuum hoses that were removed.
    6.  
    7. Install the EPR/EGR valve bracket. Reconnect the hoses.
    8.  
    9. Install the alternator bracket bolt.
    10.  
    11. Install the air cleaner assembly.
    12.  
    13. Connect both batteries.
    14.  

    1996-98 models

    See Figure 12

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the fuel filter.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the thermostat bolts.
    8.  
    9. Remove the fuel line return hose and its retaining clips.
    10.  

    Mark the location of the EGR/boost or boost (whichever your vehicle is equipped with) solenoid studs so that they can be installed in their original positions.

    1. Remove the EGR/boost or boost (whichever your vehicle is equipped with) solenoids with the bracket from the intake manifold studs.
    2.  
    3. Remove the heater hose bracket and the vacuum hoses from the EGR valve.
    4.  
    5. Remove the long pencil brace that attaches to the turbocharger.
    6.  
    7. Remove the upper radiator hose.
    8.  
    9. Remove the fuel filter assembly and the POE wiring harness bracket to the rear of the lower intake manifold.
    10.  
    11. Remove the intake manifold that runs from the turbocharger to the upper intake manifold.
    12.  
    13. Mark the location of the fuel line clips and brackets so that they can be installed in their original positions.
    14.  
    15. Remove the intake manifold studs and the fuel line clips.
    16.  
    17. Remove the intake manifold and the gasket.
    18.  
    19. If any further work is to performed around the intake manifold area, cover the intake ports to prevent any dirt entering the ports.
    20.  
    21. Use a scraper to clean the gasket mating surfaces.
    22.  

    To install:

    Be sure to use the correct gasket, the engines that utilize an EGR valve should have an opening in the gasket. Likewise the vehicles that are not equipped with an EGR valve should not have an EGR valve opening in the gasket.

    1. Remove any covers placed over the intake ports to prevent dirt from entering the ports.
    2.  
    3. Install the new gaskets and the intake manifold.
    4.  
    5. Apply Teflon® sealer to bolts 9, 11, 13 and 15, as these bolts are exposed to the crankcase.
    6.  
    7. Apply a threadlocker sealer to bolts 1, 2, 3 , 4, 5, 6 , 7, 8, 10, 12, 14 and 16.
    8.  
    9. Install the intake manifold studs and the fuel line clips. Tighten the studs to 31 ft. lbs. (42 Nm) in the sequence illustrated.
    10.  
    11. Install the upper intake manifold.
    12.  
    13. If equipped, install the EGR tower gasket on the round center portion of the upper intake manifold.
    14.  
    15. Slide the upper intake manifold into the turbocharger outlet hose.
    16.  
    17. Apply a suitable silicone sealant to the turbocharger outlet before you install the turbocharger outlet onto the upper manifold.
    18.  
    19. Install the clamp for the turbocharger connector hose and tighten the connector hose clamps to 50 inch lbs. (6 Nm).
    20.  
    21. Install the fuel line bracket and the ground straps.
    22.  
    23. Attach the upper radiator hose.
    24.  
    25. If equipped, attach the pencil brace to the turbocharger.
    26.  

    When installing the upper intake manifold, if equipped with an O-ring between the upper and lower manifolds, always replace this O-ring as failure to do so could cause a derivability problem.

    1. Attach the vacuum hoses and the install heater hose bracket.
    2.  
    3. Install the EGR/boost solenoids with the bracket onto the intake manifold studs.
    4.  
    5. Install the fuel return line hose and the fuel filter. Tighten the fuel filter bolts to 31 ft. lbs. (42 Nm).
    6.  
    7. Install the thermostat bolts.
    8.  
    9. Connect the negative battery cables.
    10.  
    11. Refill the cooling system.
    12.  
    13. Start the engine and check for fluid leaks.
    14.  



    Click image to see an enlarged view

    Fig. Fig. 12: Intake manifold tightening sequence-1997-98 models

    7.4L Engines
    1988-95 MODELS

    See Figures 13, 14 and 15

    1. Disconnect the battery.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the air cleaner assembly.
    6.  
    7. Remove the upper radiator hose, thermostat housing and the bypass hose, if necessary.
    8.  
    9. Disconnect the heater hose and pipe.
    10.  
    11. Tag and disconnect all electrical connections and vacuum lines from the manifold and move them to the side.
    12.  
    13. Disconnect the accelerator linkage.
    14.  
    15. Disconnect the cruise control cable, if equipped.
    16.  
    17. Disconnect the TVS cable.
    18.  
    19. Remove the fuel line at the manifold.
    20.  
    21. Remove the TBI unit, if necessary. Refer to Fuel Systems for this procedure.
    22.  

    Mark the relationship of the distributor and rotor for proper reassembly

    1. Remove the distributor, if necessary.
    2.  
    3. Remove the cruise control transducer, if equipped.
    4.  
    5. Disconnect the ignition coil wires and remove the coil if necessary.
    6.  
    7. Remove the EGR solenoid and bracket.
    8.  
    9. Remove the MAP sensor and bracket.
    10.  
    11. Remove the air conditioning compressor rear bracket.
    12.  
    13. Remove the front alternator/AIR pump bracket, if necessary.
    14.  
    15. Remove the intake manifold bolts.
    16.  
    17. Remove the manifold and the gaskets and seals.
    18.  

    Remember to reinstall the O-ring between the intake manifold and timing chain cover during assembly, if so equipped.

    To install:

    Before installing the intake manifold, be sure that the gasket surfaces are thoroughly clean.

    1. Install the manifold and the gaskets and seals.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 13: Intake manifold bolt tightening sequence-1988-90 7.4L engines



    Click image to see an enlarged view

    Fig. Fig. 14: Intake manifold bolt tightening sequence-1991-94 7.4L engines



    Click image to see an enlarged view

    Fig. Fig. 15: Intake manifold bolt tightening sequence-1995 7.4L engines

    1. Install the intake manifold bolts. Tighten the bolts to 30 ft. lbs. (40 Nm) in the proper sequence.
    2.  
    3. Install the front alternator/AIR pump bracket, if removed.
    4.  
    5. Install the air conditioning compressor rear bracket, if removed.
    6.  
    7. Install the MAP sensor and bracket.
    8.  
    9. Install the EGR solenoid and bracket.
    10.  
    11. Connect the ignition coil wires.
    12.  
    13. Install the cruise control transducer, if equipped.
    14.  
    15. Install the distributor.
    16.  
    17. Install the TBI unit, if removed. Refer to Fuel Systems for this procedure.
    18.  
    19. Install the fuel line at the manifold.
    20.  
    21. Connect the TVS cable.
    22.  
    23. Connect the cruise control cable, if equipped.
    24.  
    25. Connect the accelerator linkage.
    26.  
    27. Connect all electrical connections and vacuum lines at the manifold.
    28.  
    29. Connect the heater hose and pipe.
    30.  
    31. Install the upper radiator hose, thermostat housing and the bypass hose.
    32.  
    33. Install the air cleaner assembly.
    34.  
    35. Fill the cooling system.
    36.  
    37. Connect the battery.
    38.  

    1996-98 MODELS

    See Figures 16

    1. Have the A/C system discharged. Recover the refrigerant using the appropriate recycling equipment.
    2.  
    3. Remove the upper intake manifold using the recommended procedure outlined in this section.
    4.  
    5. Remove the A/C lines at the compressor.
    6.  
    7. Remove the distributor using the recommended procedure. Mark the relationship of the distributor housing and rotor for proper reassembly.
    8.  


    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

    1. Drain the engine coolant. Remove the upper radiator hose at the thermostat housing.
    2.  
    3. Disconnect the heater hose from the manifold.
    4.  
    5. Disconnect the fuel line brackets and rail.
    6.  
    7. Disconnect the water pump by-pass hose.
    8.  
    9. Unfasten the lower intake manifold bolts and remove the lower intake manifold and gaskets.
    10.  

    To install:
    1. Clean all parts well:
      1. Clean all traces of gasket from the sealing surfaces.
      2.  
      3. Inspect for cracks, broken flanges and gasket surface damage.
      4.  
      5. Clean excessive carbon buildup in the exhaust passages.
      6.  
      7. Clean scale and deposits from the coolant passages.
      8.  
      9. Clean the EGR passage of carbon deposits.
      10.  

    2.  
    3. Install the gaskets to the cylinder head in their proper position. Factory-type gaskets should be stamped "This Side Up".
    4.  
    5. Install the front and rear intake manifold seals to the block.
    6.  
    7. Apply a 3 / 16 -inch (5mm) bead of RTV GM #1052289, or equivalent, to the four seal corners of the block. Extend the bead approximately 1 / 2 -inch (13mm) up the cylinder head to seal and retain the gaskets.
    8.  
    9. Carefully place the lower intake manifold into position on the engine.
    10.  
    11. Apply sealer, GM #1052080, or equivalent, to the lower intake manifold bolts. Install the lower manifold bolts and tighten them in sequence to 30 ft. lbs. (40 Nm).
    12.  
    13. Install the water pump by-pass hose.
    14.  
    15. Install the wiring harness connectors and brackets.
    16.  
    17. Install the fuel line brackets and fuel rail.
    18.  
    19. Install the heater hose.
    20.  
    21. Install the upper radiator hose.
    22.  
    23. Install the A/C lines to the compressor.
    24.  
    25. Install the distributor. Note the relationship of the distributor housing and rotor made at disassembly.
    26.  
    27. Install the upper intake manifold using the procedure in this section.
    28.  
    29. Fill the cooling system.
    30.  

    The 1996-98 models should have come with DEX-COOL®. This orange-color coolant is low in silicates and is designed to protect the aluminum components in the cooling system.

    1. Connect the negative battery cable.
    2.  
    3. Start the engine. Check for coolant, oil and vacuum leaks and for proper engine operation.
    4.  
    5. Have the A/C system recharged.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 16: Upper and Lower intake manifold bolt tightening sequence-1996-98 models

     
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