GM Camaro 1982-1992 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



When servicing all vehicles, be absolutely sure to mark vacuum hoses and wiring so that these items may be properly reconnected during installation. Also, when disconnecting fitting lines (fuel lines, power brake vacuum lines, transmission and engine cooler lines, etc.), always use two flare nut (or line) wrenches. Hold the wrench on the large fitting with pressure on the wrench as if you were tightening the fitting (clockwise), THEN loosen and disconnect the smaller fitting from the larger fitting. If this is not done, damage to the line will result. Always relieve fuel system pressure before disconnecting lines.


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2.5L Engine

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Intake manifold bolt torque sequence for 2.5L engine

  1. Disconnect the negative battery cable at the battery.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the PCV valve and hose.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect the fuel lines from the Throttle Body Injection (TBI) unit.
  10.  
  11. Mark and disconnect the vacuum lines and the electrical connections from the TBI unit.
  12.  
  13. Disconnect the linkage from the TBI unit (throttle, downshift, and/or cruise control, as applicable).
  14.  
  15. Disconnect the coolant inlet and outlet hoses from the intake manifold.
  16.  
  17. Remove the air conditioning compressor support brackets and the compressor. DO NOT disconnect the refrigerant lines from the compressor. Lay the compressor aside.
  18.  
  19. Remove the manifold attaching bolts and remove the manifold.
  20.  

To install:
  1. Position the manifold into place and install manifold attaching bolts. Torque manifold bolts to specification (see illustration for tightening sequence and torque specifications).
  2.  
  3. Install the air conditioning compressor and compressor support brackets, if so equipped.
  4.  
  5. Connect the coolant inlet and outlet hoses to the intake manifold.
  6.  
  7. Connect the linkage to the TBI unit (throttle, downshift, and/or cruise control, as applicable).
  8.  
  9. Connect the vacuum lines and the electrical connections to the TBI unit.
  10.  
  11. Connect the fuel lines to the Throttle Body Injection (TBI) unit.
  12.  
  13. Install the PCV valve and hose.
  14.  
  15. Install the air cleaner assembly.
  16.  
  17. Connect the negative battery cable at the battery.
  18.  
  19. Fill the cooling system.
  20.  

2.8L and 5.0L Carbureted Engines

See Figures 2 through 6



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Fig. Fig. 2: Intake manifold bolt removal



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Fig. Fig. 3: Prying loose the manifold



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Fig. Fig. 4: Lifting off the manifold



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Fig. Fig. 5: Intake manifold bolt torque sequence for the carbureted 2.8L



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Fig. Fig. 6: Intake manifold bolt torque sequence for V8 engines, except Crossfire Fuel Injection

  1. Remove the air cleaner.
  2.  
  3. Drain the radiator.
  4.  
  5. Disconnect:
    1. Battery cables at the battery.
    2.  
    3. Upper radiator and heater hoses at the manifold.
    4.  
    5. Crankcase ventilation hoses as required.
    6.  
    7. Fuel line at the carburetor.
    8.  
    9. Accelerator linkage.
    10.  
    11. Vacuum hose at the distributor, if equipped.
    12.  
    13. Power brake hose at the carburetor base or manifold, if applicable.
    14.  
    15. Temperature sending switch wires.
    16.  

  6.  
  7. Remove the distributor cap and scribe the rotor position relative to the distributor body, and engine.
  8.  
  9. Remove the distributor.
  10.  
  11. If applicable, remove the alternator upper bracket. As required, remove the air cleaner bracket, and accelerator bellcrank.
  12.  
  13. Remove the manifold-to-head attaching bolts, then remove the manifold and carburetor as an assembly.
  14.  
  15. Mark and disconnect all emission related items (e.g.: wiring, vacuum hoses, etc.) which are connected to manifold mounted items.
  16.  
  17. If the manifold is to be replaced, transfer the carburetor (and mounting studs), water outlet and thermostat (use a new gasket) heater hose adapter, EGR valve (use new gasket) and, if applicable, TVS switch(s) and the choke coil.
  18.  

To install:
  1. Before installing the manifold, thoroughly clean the gasket and sealing surfaces of the cylinder heads and manifold.
  2.  
  3. Install the manifold end seals, folding the tabs if applicable, and the manifold/head gaskets, using a sealing compound around the water passages.
  4.  

Make sure that the new manifold gaskets match the old ones EXACTLY.

  1. When installing the manifold, care should be taken not to dislocate the end seals. It is helpful to use a pilot in the distributor opening. Tighten the manifold bolts to 30 ft. lbs. (40 Nm) for 5.0L or 20-25 ft. lbs. (27-34 Nm) for 2.8L in the sequence illustrated.
  2.  
  3. Install the distributor with the rotor in its original location as indicated by the scribe line. If the engine has been disturbed, refer to the previous Distributor Removal and Installation procedure.
  4.  
  5. If applicable, install the alternator upper bracket and adjust the belt tension.
  6.  
  7. Connect all disconnected components at their original locations.
  8.  
  9. Fill the cooling system, start the engine, check for leaks and adjust the ignition timing and carburetor idle speed and mixture.
  10.  

TBI Equipped 5.0L Engine
1982-1983 CROSSFIRE FUEL INJECTION MODELS

See Figures 7 and 8



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Fig. Fig. 7: Crossfire injection upper plenum and gasket

  1. Disconnect the negative battery cable at the battery.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the fuel inlet line.
  8.  
  9. Remove the exhaust gas recirculation (EGR) solenoid.
  10.  
  11. Disconnect the wiring from the idle air motors, injectors, and the throttle position sensor (TPS).
  12.  
  13. Disconnect the fuel return line at the rear TBI unit.
  14.  
  15. Remove the power brake booster line.
  16.  
  17. Disconnect the accelerator and cruise control cables, unbolt the cable bracket from the manifold and tie the cable and bracket assembly out of the way.
  18.  
  19. Disconnect the positive crankcase ventilation valve hose at the manifold and move the hose aside.
  20.  
  21. Mark and disconnect any vacuum hoses which will interfere with removal of the manifold.
  22.  
  23. If you plan on removing the TBI units from the upper manifold plate, remove the fuel balance tube (connecting the units) at this time.
  24.  
  25. Remove the bolts which attach the upper manifold plate (or TBI plate) to the intake manifold. Lift the TBI and plate assembly off of the intake manifold.
  26.  
  27. Remove the distributor as previously outlined.
  28.  
  29. Disconnect the upper radiator hose from the thermostat housing.
  30.  
  31. Disconnect the heater hose from the intake manifold.
  32.  
  33. Remove the intake manifold-to-cylinder head bolts and lift the intake manifold assembly off of the engine.
  34.  

To install:
  1. Clean the sealing surfaces.
  2.  
  3. Install the gaskets and apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear ridge of the cylinder case.
  4.  
  5. Hold the gaskets in place by extending the RTV bead up onto the gasket ends. Use sealer at the water passages.
  6.  
  7. Position the intake manifold assembly onto the engine and install the intake manifold-to-cylinder head bolts. Torque bolts in sequence to 25-45 ft. lbs. (34-61 Nm).
  8.  
  9. Connect the heater hose to the intake manifold.
  10.  
  11. Connect the upper radiator hose to the thermostat housing.
  12.  
  13. Install the distributor.
  14.  
  15. Position the TBI and plate assembly on the intake manifold with a new gasket. Install the bolts which attach the upper manifold plate (or TBI plate) to the intake manifold and torque to specification.
  16.  
  17. If the TBI units on CFI engines were removed, install the fuel balance tube (connecting the units).
  18.  
  19. Connect vacuum hoses which were disconnected for removal of the manifold.
  20.  
  21. Connect the positive crankcase ventilation valve hose.
  22.  
  23. Install the cable bracket to the manifold and connect the accelerator and cruise control cables.
  24.  
  25. Install the power brake booster line.
  26.  
  27. Connect the fuel return line at the TBI unit.
  28.  
  29. Connect the wiring to the idle air motors, injectors, and the throttle position sensor (TPS).
  30.  
  31. Install the exhaust gas recirculation (EGR) solenoid.
  32.  
  33. Connect the fuel inlet line to the TBI unit.
  34.  
  35. Install the air cleaner assembly.
  36.  
  37. Connect the negative battery cable at the battery.
  38.  
  39. Fill the cooling system.
  40.  
  41. Start the engine and check for leaks.
  42.  



Click image to see an enlarged view

Fig. Fig. 8: Crossfire fuel injection intake manifold bolt torque sequence

1988-1992 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the throttle body.
  8.  
  9. Label and unplug all vacuum hose and electrical connections on the manifold.
  10.  
  11. Disconnect the upper radiator hose from the manifold.
  12.  
  13. Mark the distributor position and remove it.
  14.  
  15. Remove the EGR valve, if necessary.
  16.  
  17. Remove the intake manifold bolts and studs.
  18.  
  19. Remove the manifold and discard the gaskets.
  20.  

To install:
  1. Make sure the sealing surfaces are clean.
  2.  
  3. Install the gaskets and apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear ridge of the cylinder block.
  4.  
  5. Hold the gaskets in place by extending the RTV bead up onto the gasket ends. Use sealer at the water passages.
  6.  
  7. Install the intake manifold.
  8.  

Sealing of the intake manifold to the "V" of the engine is obtained by employing an intermediate torque specification to all the attaching bolts, alternately, in the proper sequence. This step is used to rock the manifold into place before applying the final torque figure. Failure to follow this two-step procedure can result in possible leaks.

  1. Install the intake manifold attaching bolts. Tighten them, using the proper sequence, to 89 in lbs. (10 Nm).
  2.  
  3. Final torque the bolts, using the proper sequence, to 35 ft lbs. (47 Nm).
  4.  
  5. Install the EGR valve.
  6.  
  7. Install the distributor.
  8.  
  9. Connect the upper radiator hose to the thermostat housing.
  10.  
  11. Install the throttle body.
  12.  
  13. Engage all electrical and hose connections.
  14.  
  15. Fill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Install the air cleaner.
  20.  

1985-1992 MFI Engines
2.8L AND 3.1L ENGINES

See Figure 9



Click image to see an enlarged view

Fig. Fig. 9: Intake manifold bolt torque sequence for 2.8L and 3.1L MFI engines

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant.
  4.  
  5. Remove the air inlet duct at the throttle body and the crankcase vent pipe.
  6.  
  7. Unplug the vacuum harness from the throttle body.
  8.  
  9. Remove the throttle body.
  10.  
  11. Remove the EGR transfer tube. Discard the gasket.
  12.  
  13. Remove the A/C compressor-to-plenum bracket attaching hardware and bracket.
  14.  
  15. Remove the plenum attaching bolts and plenum. Discard the gaskets.
  16.  
  17. Remove the fuel rail.
  18.  
  19. Label and unplug the wires from the spark plugs.
  20.  
  21. Label and unplug the wires at the coil.
  22.  
  23. Remove the distributor cap and spark plug wires.
  24.  
  25. Mark the distributor position and remove it.
  26.  
  27. Label and disconnect the emission canister hoses.
  28.  
  29. Remove the valve covers.
  30.  
  31. Remove the upper radiator hose at the manifold.
  32.  
  33. Unplug the coolant switch and sensor.
  34.  
  35. Remove the heater inlet pipe from the manifold.
  36.  
  37. Remove the center intake manifold bolts.
  38.  
  39. Remove the center intake manifold and gasket. Discard the gasket.
  40.  
  41. Remove the transmission dipstick.
  42.  
  43. Remove the manifold bolts.
  44.  
  45. Remove the manifold. Discard the gaskets and remove the RTV sealant from the front and rear ridges of the block.
  46.  

To install:
  1. Apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear ridges of the block. Make sure the surfaces are clean.
  2.  
  3. Install the new gaskets on the cylinder heads. Hold the gaskets in place by extending the RTV bead up onto the gasket ends. Certain GM intake gaskets will have to be cut to be install behind the pushrods. Cut these gaskets as required and only where necessary.
  4.  
  5. Install the intake manifold along with the intake manifold bolts. Torque bolts in sequence to 13-25 ft. lbs. (18-34 Nm) on 2.8L engines and 19 ft lbs. (26 Nm) on 3.1L engines.
  6.  
  7. Install the center intake manifold with a new gasket. Tighten the bolts to 15 ft lbs. (21 Nm).
  8.  
  9. Connect the coolant switches.
  10.  
  11. Install the upper radiator hose.
  12.  
  13. Install the valve covers.
  14.  
  15. Install the heater inlet pipe.
  16.  
  17. Connect the emission canister hoses.
  18.  
  19. Install the distributor to the matchmarks, hold down bolt, spark plug wires and distributor cap.
  20.  
  21. Install the spark plug wires to the spark plugs and connect the wires at the coil.
  22.  
  23. Install the fuel rail.
  24.  
  25. Install the plenum with new gaskets. Tighten the bolts to 18 ft lbs. (25 Nm) on 2.8L engines or 15 ft lbs. (21 Nm) on 3.1L engines.
  26.  
  27. Install the A/C compressor-to-plenum bracket and attaching hardware.
  28.  
  29. Install the EGR transfer tube with a new gasket. Tighten the bolts to 19 ft lbs. (26 Nm).
  30.  
  31. Install the throttle body.
  32.  
  33. Connect the vacuum harness and air inlet duct to the throttle body.
  34.  
  35. Install the transmission dipstick.
  36.  
  37. Connect and other remaining hoses or wires.
  38.  
  39. Fill the cooling system.
  40.  
  41. Start the engine and check for proper operation.
  42.  

5.0L AND 5.7L ENGINES

See Figure 10



Click image to see an enlarged view

Fig. Fig. 10: Intake manifold bolt torque sequence for V8 engines, except Crossfire Fuel Injection

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake duct.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the control cables from the throttle body.
  8.  
  9. Label and unplug all wiring connectors and hoses from the throttle body and plenum.
  10.  
  11. Disconnect the AIR hoses from the air management valve.
  12.  
  13. Disconnect the fuel lines.
  14.  
  15. Label and unplug the spark plug wires at the cap.
  16.  
  17. Mark the distributor position and remove it.
  18.  
  19. Unplug the injector wiring harness.
  20.  
  21. Remove the left side runner-to-plenum bolts.
  22.  
  23. Remove the left side runner-to-manifold bolts.
  24.  
  25. Remove the right side runner-to-plenum bolts.
  26.  
  27. Remove the right side runner-to-manifold bolts.
  28.  
  29. Remove the EGR solenoid, if necessary.
  30.  
  31. Remove the right side manifold-to-runner bolt.
  32.  
  33. Remove the plenum, right side runners and gaskets. Discard the gaskets.
  34.  
  35. Remove the left side manifold-to-runner bolt.
  36.  
  37. Remove the left side runners and gaskets. Discard the gaskets.
  38.  
  39. Disconnect the upper radiator hose from the thermostat housing.
  40.  
  41. Remove the EGR valve, if necessary.
  42.  
  43. Unplug any other electrical or hose connections, as necessary.
  44.  
  45. Remove the intake manifold bolts.
  46.  
  47. Remove the intake manifold and gaskets. Discard the gaskets.
  48.  

To install:
  1. Apply a 3 / 16 in. (5mm) bead of RTV sealant on the front and rear ridges of the block. Make sure the surfaces are clean.
  2.  
  3. Install the new gaskets on the cylinder heads. Hold the gaskets in place by extending the RTV bead up onto the gasket ends.
  4.  
  5. Install the intake manifold.
  6.  

Sealing of the intake manifold to the "V" of the engine is obtained by employing an intermediate torque specification to all the attaching bolts, alternately, in the proper sequence. This step is used to rock the manifold into place before applying the final torque figure. Failure to follow this two-step procedure can result in possible leaks.

  1. Install the intake manifold attaching bolts. Tighten them, using the proper sequence, to 89 in lbs. (10 Nm).
  2.  
  3. Final torque the bolts, using the proper sequence, to 35 ft lbs. (47 Nm).
  4.  
  5. Install the EGR valve using a new gasket.
  6.  
  7. Connect the upper radiator hose to the thermostat housing.
  8.  
  9. Install new gaskets on the runners and intake manifold. Make sure the gasket sealing surfaces are clean.
  10.  
  11. Install the left side runners and finger-tighten the runner-to-manifold bolts.
  12.  
  13. Install the left side manifold-to-runner bolt. Torque to 25 ft lbs. (34 Nm).
  14.  
  15. Install the right side runners. Finger-tighten the runner-to-manifold and manifold-to-runner bolts.
  16.  
  17. Install the plenum and the runner-to-plenum bolts.
  18.  
  19. Tighten the runner-to-manifold bolts to 25 ft lbs. (34 Nm). Start in the center and work outwards.
  20.  
  21. Tighten the right side manifold-to-runner bolt to 25 ft lbs. (34 Nm).
  22.  
  23. Tighten the runner to plenum bolts to 25 ft lbs. (34 Nm). Start in the center and work outwards.
  24.  
  25. Install the distributor.
  26.  
  27. Connect the fuel lines.
  28.  
  29. Install the EGR valve solenoid.
  30.  
  31. Connect the control cables to the throttle body.
  32.  
  33. Connect all remaining hose and wiring connections.
  34.  
  35. Fill the cooling system.
  36.  
  37. Connect the negative battery cable.
  38.  

 
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