GM Caprice 1990-1993 Repair Guide

Intake Manifold

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REMOVAL AND 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.

5.0L (VIN Y) ENGINE

See Figures 1 and 2



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Fig. Fig. 1: Intake manifold bolt torque sequence - 5.0L (VIN Y) engine



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Fig. Fig. 2: Intake manifold installation - 5.0L (VIN Y) engine

  1. Disconnect the negative battery cable and drain the radiator.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Disconnect hoses and pipes; upper radiator, thermostat by-pass at water pump, heater at rear of manifold, fuel, vacuum (label each hose) and AIR.
  6.  
  7. Disconnect the throttle and TV cables.
  8.  
  9. Remove generator rear brace and air conditioning rear brace.
  10.  
  11. Disconnect all necessary electrical leads.
  12.  
  13. Disconnect rear vacuum brake/idle load compensator/exhaust gas recirculation solenoid assembly and idle load compensator and bracket assembly.
  14.  
  15. Disconnect EGR valve.
  16.  
  17. Remove intake manifold bolts and manifold.
  18.  

To install:
  1. Clean mating surfaces and discard old gaskets.
  2.  
  3. Apply 1050026 sealer or equivalent, to both sides of the manifold gasket. Then apply 1052915 or equivalent RTV sealer, to the front and rear seals.
  4.  
  5. Place gaskets on cylinder heads and seals to block.
  6.  
  7. Position intake manifold, taking care not to dislodge gaskets.
  8.  
  9. Lubricate bolts with engine oil, and torque in proper sequence. First tighten all bolts to 15 ft. lbs. (20 Nm), then tighten to 40 ft. lbs. (54 Nm).
  10.  
  11. Connect EGR valve and tighten bolts to 20 ft. lbs. (27 Nm).
  12.  
  13. Connect electrical leads.
  14.  
  15. Connect air conditioning and generator braces.
  16.  
  17. Connect throttle and TV cables.
  18.  
  19. Connect hoses and pipes; AIR, vacuum, fuel, heater and upper radiator.
  20.  
  21. Install air cleaner and connect the negative battery cable.
  22.  
  23. Fill cooling system and inspect for leaks.
  24.  

4.3L, 5.0L (VIN E) AND 5.7L ENGINES

See Figures 3 and 4



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Fig. Fig. 3: Intake manifold torque sequence - 4.3L engine



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Fig. Fig. 4: Intake manifold torque sequence - 5.0L (VIN E) and 5.7L engine

  1. Properly relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant into a suitable container and remove the air cleaner.
  4.  
  5. Remove the throttle body assembly, if necessary.
  6.  
  7. Disconnect the ECM engine control harness and lay it aside.
  8.  
  9. Disconnect the upper radiator hose at thermostat housing and heater hose at the manifold.
  10.  
  11. Remove thermostat housing and gasket, if necessary.
  12.  
  13. Disconnect all necessary electrical connections.
  14.  
  15. Disconnect fuel pipe clips at AIR pump bracket and intake manifold.
  16.  
  17. Disconnect accelerator and TV cables.
  18.  
  19. Remove the spark plug wires at the distributor cap. Mark 1 wire and location to assist in reinstallation.
  20.  
  21. Remove the EGR valve and EGR solenoid valve, as applicable.
  22.  
  23. Remove the distributor cap and mark the position of the rotor, then remove the distributor. Remove the coil and bracket as required.
  24.  
  25. Remove the accessory mounting brackets, as required.
  26.  
  27. Remove the coolant temperature sensor.
  28.  
  29. Remove the manifold bolts, studs and remove the intake manifold. Remove and discard the intake manifold gaskets.
  30.  

To install:
  1. Thoroughly clean the intake manifold and cylinder block surfaces to remove any trace of gasket material or sealant.
  2.  
  3. Place gasket and seals on cylinder heads and block, apply a thin bead of RTV sealer 1052289 or equivalent, to the front and rear of cylinder block. Extend the RTV bead 1 / 2 inch up each cylinder head to seal and retain gasket.
  4.  
  5. Install the intake manifold, manifold retaining bolts and studs taking care not to dislodge the gaskets and seals. Tighten bolts and studs in proper sequence, first to 10 ft. lbs. (14 Nm) and then to 35 ft. lbs. (47 Nm).
  6.  
  7. Install coolant temperature sensor.
  8.  
  9. Attach accessory mounting brackets, if removed. Tighten compressor brace to manifold nut to 18 ft. lbs. (24 Nm), compressor brace to compressor nut to 24 ft. lbs. (32 Nm) and/or generator to brace nut to 37 ft. lbs. (50 Nm)
  10.  
  11. Install distributor, align rotor with mark and attach cap. Attach coil and bracket if removed.
  12.  
  13. Install the EGR valve and EGR solenoid valve, as applicable.
  14.  
  15. Attach the spark plug wires to the distributor cap in proper firing order.
  16.  
  17. Connect the accelerator and TV cables.
  18.  
  19. Connect fuel pipe clips to AIR pump bracket and intake manifold.
  20.  
  21. Connect all necessary electrical connections.
  22.  
  23. Install the thermostat housing and gasket, if removed. Connect the upper radiator hose to the thermostat housing and heater hose at the manifold.
  24.  
  25. Connect the ECM engine control harness.
  26.  
  27. Install the throttle body assembly, if removed.
  28.  
  29. Install the air cleaner and connect the negative battery cable.
  30.  
  31. Replace fuel filler cap and add engine coolant.
  32.  
  33. Start the engine and inspect for leaks. Adjust timing if necessary.
  34.  

 
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