Chevrolet Citation/Omega/Phoenix/Skylark 1980-1985 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



Four Cylinder


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Fig. Fig. 1 Intake manifold mounting-4-cylinder engine



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Fig. Fig. 2 When removing the intake manifold, remove the accelerator and throttle valve cables



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Fig. Fig. 3 Unfasten the clamp, then disconnect the heater hose from the intake manifold



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Fig. Fig. 4 Unfasten the intake manifold retaining bolts ...



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Fig. Fig. 5 ... then remove the intake manifold from the vehicle



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Fig. Fig. 6 Remove and discard the intake manifold gasket



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Fig. Fig. 7 During installation, you must follow the intake manifold bolt tightening sequence

Bleed pressure from the fuel system, if equipped with fuel injection, before servicing. See , Electric Fuel Pump.

  1. Remove the air cleaner and the PCV valve.
  2.  
  3. Drain the cooling system into a clean container.
  4.  
  5. Disconnect and label the fuel and vacuum lines and the electrical connections at the carburetor and the manifold.
  6.  
  7. Disconnect the accelerator cable and the throttle valve cables from the carburetor or TBI unit.
  8.  
  9. Remove the carburetor and the spacer.
  10.  
  11. Remove the bell crank and the throttle linkage. Position to the side for clearance.
  12.  
  13. Remove the heater hose at the intake manifold.
  14.  
  15. Remove the air system check valve bracket from the manifold.
  16.  
  17. Remove the manifold attaching bolts and remove the manifold.
  18.  
  19. To install, reverse the removal procedure. Always use a new gasket. Tighten all the bolts in two stages to 25 ft. lbs. in the proper sequence.
  20.  

Six Cylinder


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Fig. Fig. 8 On the V6, cut the intake manifold gasket as necessary to slip it past the inner pushrods



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Fig. Fig. 9 Removing the intake manifold-6-cylinder engine shown



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Fig. Fig. 10 Intake manifold bolt tightening sequence-6-cylinder engine

  1. Remove the rocker covers.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the distributor cap. Mark the position of the ignition rotor in relation to the distributor body and remove the distributor. Do not crank the engine with the distributor removed.
  6.  
  7. Remove the heater and radiator hoses from the intake manifold.
  8.  
  9. Remove the power brake vacuum hose.
  10.  
  11. Disconnect and label the vacuum hoses. Remove the EFE pipe from the rear of the manifold.
  12.  
  13. Remove the carburetor linkage. Disconnect and plug the fuel line.
  14.  
  15. Remove the manifold retaining bolts and nuts.
  16.  
  17. Remove the intake manifold. Remove and discard the gaskets, and scrape off the old silicone seal from the front and rear cylinder case ridges.
  18.  

To install:

  1. The gaskets are marked for right and left side installation; do not interchange them. Clean the sealing surface of the engine block, and apply a 3 / 16 in. bead of silicone sealer to each ridge.
  2.  
  3. Install the new gaskets onto the heads. The gaskets will have to be cut slightly to fit past the center pushrods. Do not cut any more material than necessary. Hold the gaskets in place by extending the ridge bead of sealer 1 / 4 in. onto the gasket ends.
  4.  
  5. Install the intake manifold. The area between the ridges and the manifold should be completely sealed.
  6.  
  7. Install the retaining bolts and nuts, and tighten in sequence to 23 ft. lbs. Do not overtighten; the manifold is made from aluminum, and can be warped or cracked with excessive force.
  8.  
  9. The rest of installation is the reverse of removal. Adjust the ignition timing after installation, and check the coolant level after the engine has warmed up.
  10.  

 
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