GM Full-Size Trucks 1980-1987 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION




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.

In-line 6-Cylinder

250 (4.1L) ENGINE

All 250 (4.1L) engines have an intake manifold which is cast integrally with the cylinder head and cannot be removed.

292 (4.8L) ENGINE
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly and air ducts.
  4.  
  5. Tag and disconnect the throttle linkage at the carburetor. Tag and disconnect the fuel line, vacuum lines, hoses, and electrical connections.
  6.  
  7. Disconnect the transmission downshift linkage (if equipped), and remove the PCV valve from the rocker cover. On models equipped with air injection, disconnect the air supply hose from the check valve on the air injection manifold.
  8.  
  9. Remove the carburetor, with spacer and heat shield (if equipped).
  10.  
  11. Spray the nuts and bolts connecting the exhaust manifold to the exhaust pipe with a rust penetrant, as these are usually quite difficult to remove. Unbolt the exhaust manifold from the pipe.
  12.  

It may be necessary to remove the generator rear bracket and/or air conditioning compressor bracket on some models.

  1. Unbolt the manifold bolts and clamps, and remove the manifold assembly.
  2.  
  3. If you intend to separate the manifolds, remove the single bolt and two nuts at the center of the manifold assembly.
  4.  
  5. Installation is the reverse of removal. When assembling the manifolds, install the connecting bolts loosely first. Place the manifolds on a straight, flat surface and hold them securely during tightening-this assures the proper mating of surfaces when the manifold assembly is fastened to the head. Stress cracking could occur if the manifolds are not assembled first in this manner. On all manifolds, always use new gaskets between the manifold and cylinder head.
  6.  

V6 and V8 Except Diesel

See Figures 1, 2, 3, 4, 5, 6, 7 and 8

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Either remove the thermostat housing and the bypass hose, or if the manifold is not being replaced, you may just disconnect the hose.
  8.  
  9. Disconnect the heater hose at the rear of the manifold.
  10.  
  11. Disconnect all electrical connections and vacuum lines from the manifold. Remove the EGR valve if necessary.
  12.  
  13. On vehicles equipped with power brakes remove the vacuum line from the vacuum booster to the manifold.
  14.  
  15. Remove the distributor (if necessary).
  16.  
  17. Move the air conditioning compressor to one side, if necessary.
  18.  



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Fig. Fig. 1: Disengage all electrical connectors from the intake manifold mounted components



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Fig. Fig. 2: A box wrench will likely be needed on a few manifold bolts where manifold components restrict access

  1. Relieve the fuel system pressure. See Routine Maintenance .
  2.  
  3. Remove the fuel line to the carburetor or TBI unit.
  4.  
  5. Remove the carburetor linkage.
  6.  
  7. Disengage the electrical connections at the TBI unit.
  8.  
  9. Remove the carburetor or TBI unit, if necessary.
  10.  



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Fig. Fig. 3: When all bolts are removed, the manifold may be lifted from the engine

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

Most intake manifolds are cast iron and heavy. It will be necessary to get a good grip before attempting to lift the manifold from the engine. Also, the gasket seal may take some leverage to break, but be very careful not to damage the mating surfaces if prying is necessary.

  1. Reconnect all wires, hoses and linkage. Use plastic gasket retainers to prevent the manifold gasket from slipping out of place, if so equipped.
  2.  

On the small block V8s, place a 3 /16 inch 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 inch up each cylinder head to seal and retain the manifold side gaskets.

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



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Fig. Fig. 4: 305 and 350 V8 intake manifold bolt torque sequence



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Fig. Fig. 5: 396 and 454 intake manifold bolt torque sequence



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Fig. Fig. 6: Gasoline V8 engine intake manifold installation



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Fig. Fig. 7: V6 engine intake manifold torque sequence



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Fig. Fig. 8: On small blocks, run a 3/16 in. bead of RTV sealer across the block and 1/2 in. up the sides of the block just prior to manifold installation

8-350 Diesel

See Figures 9, 10, 11, 12, 13, 14, 15 and 16

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Drain the radiator. Loosen the upper bypass hose clamp, remove the thermostat housing bolts, and remove the housing and the thermostat from the intake manifold.
  6.  
  7. Remove the breather pipes from the rocker covers and the air crossover. Remove the air crossover.
  8.  
  9. Disconnect the throttle rod and the return spring. If equipped with cruise control, remove the servo.
  10.  
  11. Remove the hairpin clip at the bellcrank and disconnect the cables. Remove the throttle cable from the bracket on the manifold; position the cable away from the engine. Disconnect and label any wiring as necessary.
  12.  
  13. Remove the alternator bracket if necessary. If equipped with air conditioning, remove the compressor mounting bolts and move the compressor aside, without disconnecting any of the hoses. Remove the compressor mounting bracket from the intake manifold.
  14.  
  15. Disconnect the fuel line from the pump and the fuel filter. Remove the fuel filter and bracket.
  16.  
  17. Remove the fuel injection pump and lines. See Fuel System , Fuel System, for procedures.
  18.  
  19. Disconnect and remove the vacuum pump or oil pump drive assembly from the rear of the engine.
  20.  
  21. Remove the intake manifold drain tube.
  22.  
  23. Remove the intake manifold bolts and remove the manifold. Remove the adapter seal. Remove the injection pump adapter.
  24.  
  25. Clean the mating surfaces of the cylinder heads and the intake manifold using a putty knife.
  26.  
  27. Coat both sides of the gasket surface that seal the intake manifold to the cylinder heads with GM sealer No. 1050026 or equivalent. Position the intake manifold gaskets on the cylinder heads. Install the end seals, making sure that the ends are positioned under the cylinder heads.
  28.  
  29. Carefully lower the intake manifold into place on the engine.
  30.  
  31. Clean the intake manifold bolts thoroughly, then dip them in clean engine oil. Install the bolts and tighten to 15 ft. lbs. in the sequence shown. Next, tighten all the bolts to 30 ft. lbs., in sequence, and finally tighten to 40 ft. lbs. in sequence.
  32.  
  33. Install the intake manifold drain tube and clamp.
  34.  
  35. Install injection pump adapter. See Fuel System . If a new adapter is not being used, skip steps 4 and 9.
  36.  



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Fig. Fig. 9: 350 diesel intake manifold installation. Note sealer application



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Fig. Fig. 10: 350 V8 diesel intake manifold torque sequence



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Fig. Fig. 11: 350 diesel intake manifold drain tube



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Fig. Fig. 12: Oil pump drive and vacuum pump, 350 diesel shown. 379 diesel pump similar



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Fig. Fig. 13: Adapter and seal details, 350 diesel



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Fig. Fig. 14: The index mark on the injection pump driven gear will be offset to the right when the No. 1 cylinder is at TDC



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Fig. Fig. 15: Adapter seal installation with the special tool



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Fig. Fig. 16: Adapter timing mark application

8-379 (6.2L) Diesel

  1. Disconnect both batteries.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the crankcase ventilator tubes, and disconnect the secondary fuel filter lines. Remove the secondary filter and adapter.
  6.  
  7. Loosen the vacuum pump hold-down clamp and rotate the pump to gain access to the nearest manifold bolt.
  8.  
  9. Remove the EPR/EGR valve bracket, if equipped.
  10.  
  11. Remove the rear air conditioning bracket, if equipped.
  12.  
  13. Remove the intake manifold bolts; the infection line clips are retained by these bolts.
  14.  
  15. Remove the intake manifold.
  16.  


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

  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. Torque the bolts in the sequence illustrated.
  2.  
  3. The secondary filter must be filled with clean diesel fuel before it is reinstalled.
  4.  
  5. Reverse the remaining removal procedures to complete the installation.
  6.  

 
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