GM S10/S15/Sonoma Pick-Ups 1982-1993 Repair Manual

Intake Manifold

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REMOVAL & INSTALLATION



1.9L Engine
  1. Disconnect the negative battery cable, then remove the air cleaner assembly.
  2.  
  3. Drain the engine cooling system to a level below the intake manifold.
  4.  
  5. Disconnect the upper radiator hose, the vacuum hose and the heater hose (from the rear of the intake manifold).
  6.  
  7. Disconnect the accelerator control cable. Disconnect the automatic choke and the solenoid electrical connectors.
  8.  
  9. From the distributor, disconnect the vacuum advance hose and the thermo-unit wiring electrical connector.
  10.  
  11. Disconnect the PCV valve from the rocker arm cover, then remove the oil level gauge guide tube-to-intake manifold bolt.
  12.  
  13. Disconnect the EGR pipe from the EGR valve adapter, the EGR valve and the adapter. Remove the nut from under the EGR valve.
  14.  
  15. Disconnect the AIR vacuum hose from the 3-way connector.
  16.  
  17. Remove the intake manifold-to-cylinder head nuts and the intake manifold from the engine.
  18.  

To install:
  1. Using a putty knife, clean the gasket mounting surfaces.
  2.  
  3. Inspect the manifold for cracks or damage. Using a straight edge and a feeler gauge, check manifold distortion on the sealing surfaces. Have the manifold surface ground if distortion exceeds 0.0157 in. (0.3988mm)
  4.  
  5. Install the intake manifold to the engine using a new gasket and sealant, then tighten the bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Connect the AIR vacuum hose to the 3-way connector.
  8.  
  9. Connect the EGR pipe to the EGR valve adapter, the EGR valve and the adapter.
  10.  
  11. Install the oil level gauge guide tube-to-intake manifold bolt, then connect the PCV valve to the rocker arm cover.
  12.  
  13. Engage the vacuum advance hose and the thermo-unit wiring electrical connector to the distributor.
  14.  
  15. Connect the accelerator control cable, then engage the automatic choke and the solenoid electrical connectors.
  16.  
  17. Connect the upper radiator hose, the vacuum hose and the heater hose (to the rear of the intake manifold).
  18.  
  19. Install the air cleaner assembly, then connect the negative battery cable.
  20.  
  21. Properly refill the engine cooling system, then check for leaks.
  22.  

2.0L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner, distributor cap, distributor hold-down nut and clamp.
  4.  
  5. Raise and support the front of the vehicle safely using jackstands. Remove the middle right hand bellhousing to block bolt and remove the wiring harness.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Tag and disconnect the vacuum hose and the primary wires from the coil.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Intake manifold mounting-2.0L engine

  1. Remove the fuel pump-to-engine bolts and allow the pump to hang. Be careful not to kink or damage the fuel lines.
  2.  
  3. If necessary for better underhood access, remove the jackstands and lower the vehicle.
  4.  
  5. Disconnect the accelerator cable, the fuel inlet line, then tag and disconnect the necessary vacuum hoses and wires. Remove the carburetor-to-intake manifold nuts, the carburetor and lift off the Early Fuel Evaporation (EFE) heater grid.
  6.  
  7. Disconnect the fuel vapor harness pipes from the cylinder head.
  8.  
  9. Disconnect the heater hose, bypass hose and any hoses and wires as necessary. Remove the intake manifold-to-cylinder head nuts/bolts, the intake manifold and the gasket.
  10.  

To install:
  1. Using a putty knife, clean the gasket mounting surfaces. Inspect the manifold for cracks, damage or distortion; if necessary, replace the intake manifold.
  2.  
  3. Install the intake manifold to the engine using a new gasket and sealant (as applicable), then tighten the intake manifold-to-cylinder head retainers to 25 ft. lbs. (34 Nm).
  4.  
  5. Connect the heater hose, bypass hose and any hoses and wires, which were removed from the intake.
  6.  
  7. Connect the fuel vapor harness pipes from the cylinder head.
  8.  
  9. Position the EFE grid and install the carburetor.
  10.  
  11. Connect the accelerator cable, the fuel inlet line, and the necessary vacuum hoses and wires.
  12.  
  13. Position the Early Fuel Evaporation (EFE) heater grid, then install the carburetor and secure with the carburetor-to-intake manifold nuts.
  14.  
  15. If lowered for underhood underhood access, raise and support the front of the truck safely using jackstands.
  16.  
  17. Reposition and secure the fuel pump.
  18.  
  19. Engage the vacuum hose and the primary wires to the coil.
  20.  
  21. Install the middle right hand bellhousing to block bolt and the wiring harness.
  22.  
  23. Remove the jackstands and carefully lower the truck.
  24.  
  25. Install the distributor distributor hold-down nut and clamp, then install the distributor cap.
  26.  
  27. Connect the negative battery cable and properly refill the engine cooling system.
  28.  
  29. Adjust the drive belts. Check and/or adjust the engine timing and idle speed, as necessary.
  30.  

2.2L Diesel Engine

See Figure 2

  1. Disconnect the negative battery cable, then remove the air cleaner assembly.
  2.  
  3. Disconnect the heater pipe bracket, the PCV valve hose, the necessary wires and clips from the intake manifold.
  4.  
  5. Remove the intake manifold-to-cylinder head bolts, then remove the intake manifold.
  6.  

To install:

In order to replace the intake manifold gasket, it is necessary to remove the exhaust manifold.

  1. If not done already, loosen and remove the exhaust manifold.
  2.  
  3. Using a putty knife, clean the gasket mounting surfaces.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Intake and exhaust manifold mounting-2.2L diesel engine

  1. Inspect the manifold for cracks, damage or distortion; if necessary, replace the intake manifold.
  2.  
  3. Using a new gasket, install the intake and exhaust manifolds onto the cylinder head. Torque the manifold-to-cylinder head nuts/bolts to 10-17 ft. lbs. (14-23 Nm). starting from the center and working outward.
  4.  
  5. Engage the wires and clips which were removed from the intake manifold,, then connect the PCV valve hose and the heater pipe bracket.
  6.  
  7. Install the air cleaner assembly and connect the negative battery cable.
  8.  

2.5L Engine

See Figure 3

The intake manifold is located on the right-side of the cylinder head.

  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system and remove the air cleaner assembly.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Intake manifold mounting-2.5L engine (note torque values only for manifolds secured with BOTH bolts and studs)

  1. Label and disconnect the wiring harnesses and connectors at the intake manifold.
  2.  
  3. Disconnect the accelerator, TVS, and cruise control cables (as equipped) with brackets.
  4.  
  5. Disconnect the EGR vacuum line.
  6.  
  7. Remove the emission sensor bracket at the manifold.
  8.  
  9. Tag and disconnect the fuel lines, vacuum lines and wiring from the TBI unit.
  10.  
  11. Disconnect the water pump bypass hose from the intake manifold.
  12.  
  13. Remove the alternator rear bracket.
  14.  
  15. Tag and disconnect the vacuum hoses and pipes from the intake manifold and the vacuum hold down at the thermostat and manifold.
  16.  
  17. If applicable, disconnect the heater hose at the intake.
  18.  
  19. Disconnect the coil wires.
  20.  
  21. Remove the intake manifold bolts, then remove the manifold from the engine.
  22.  

To install:
  1. Using a putty knife, clean the gasket mounting surfaces.
  2.  
  3. Installation the intake manifold to the engine using a new gasket and carefully thread the retainers.
  4.  
  5. Earlier model 2.5L engines use a manifold retained by bolts and studs, for these engines (used through the mid-1980's) tighten the retainers 25-37 ft. lbs. (34-50 Nm) using the sequence and torque values for each fastener as shown in the illustration. For later model engines which are retained only by bolts, slowly and evenly tighten all of the retainers to 25 ft. lbs. (34 Nm).
  6.  
  7. Engage the coil wires.
  8.  
  9. If applicable, connect the heater hose at the intake.
  10.  
  11. Connect the vacuum hoses and pipes to the manifold and the vacuum hold down at the thermostat as noted during removal.
  12.  
  13. Install the alternator rear bracket, then connect the coolant bypass hose.
  14.  
  15. Connect the fuel lines, vacuum lines and the wiring to the TBI unit.
  16.  
  17. Install the emissions sensor bracket, then connect the EGR valve hose.
  18.  
  19. Connect the accelerator, TVS and cruise control cables (as equipped) with brackets.
  20.  
  21. Engage and secure the wiring harness connectors at the intake, as noted during removal.
  22.  
  23. Install the air cleaner assembly, then connect the negative battery cable.
  24.  
  25. Properly refill the engine cooling system, then check for leaks.
  26.  

2.8L Engine

See Figures 4 through 16

  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system and remove the air cleaner.
  4.  
  5. Tag and disengage the electrical connectors, vacuum hoses, fuel lines and accelerator cable(s) from the carburetor or TBI unit, as applicable.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: Intake manifold mounting and torque sequence-2.8L engine

  1. If equipped with an AIR management system, remove the hose and the mounting bracket.
  2.  
  3. Label and disconnect the spark plug wires from the spark plugs and the electrical connectors from the ignition coil. Disconnect the coolant switch electrical connectors on the intake manifold.
  4.  
  5. Remove the distributor cap (with the wires connected). Matchmark and remove the distributor from the intake manifold and engine. For details, please refer to the procedures located earlier in this Section.
  6.  

DO NOT crank the engine with the distributor removed or distributor installation will be more difficult.

  1. Disconnect the EGR vacuum line and the evaporative emission hoses. Remove the pipe brackets from the rocker arm covers.
  2.  
  3. Remove the heater and upper radiator hoses from the intake manifold.
  4.  
  5. If equipped, remove the power brake vacuum hoses from the intake manifold.
  6.  
  7. Remove the rocker arm covers.
  8.  
  9. Remove the intake manifold-to-engine nuts and bolts, then the intake manifold from the engine.
  10.  

To install:
  1. Using a putty knife, clean the mating surfaces of remaining gasket and sealer. Take extra care to keep gasket debris out of the lifter valley and the rest of the engine. Since the manifold is made from aluminum, be sure to inspect it for warpage and/or cracks; if necessary, replace it.
  2.  
  3. Position new intake manifold gaskets to the engine and apply a 3 / 16 in. (5mm) bead of RTV sealant to the front and rear of the engine block.
  4.  

The gaskets are marked "Right-Side'' and "Left-Side''; DO NOT interchange them. The gaskets may 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 sealer1/4in. onto the gasket ends.

  1. Position the intake manifold taking care not to disturb the gaskets. Make sure the areas between the case ridges and the intake manifold are completely sealed, then carefully thread the retainers. For 1993 engines, before threading the 2 center retainers (No.s 1 and 2 in the torque sequence) apply a coating of 9985427 or an equivalent sealer to the threads.
  2.  
  3. Tighten the intake manifold-to-cylinder head fasteners to 23 ft. lbs. (31 Nm) using the proper torque sequence.
  4.  
  5. Install the rocker arm covers.
  6.  
  7. If equipped, connect the power brake vacuum hoses at the intake manifold.
  8.  
  9. Connect the heater and upper radiator hoses from the intake manifold.
  10.  
  11. Install the pipe brackets to the rocker arm covers, then Disconnect the EGR vacuum line and the evaporative emission hoses.
  12.  
  13. Align the marks made during removal and install the distributor assembly, then install the distributor cap and spark plug wires.
  14.  
  15. Engage the electrical connectors to the ignition coil and to the coolant switch on the intake manifold.
  16.  
  17. If equipped with an AIR management system, install the hose and the mounting bracket.
  18.  
  19. Engage the electrical connectors, vacuum hoses, fuel lines and the accelerator cable(s) to the carburetor or TBI unit, as applicable.
  20.  
  21. Install the air cleaner assembly, then connect the negative battery cable.
  22.  
  23. Properly refill the engine cooling system, then check for leaks.
  24.  
  25. Adjust the ignition timing, the idle speed (if possible) and check the coolant level after the engine has warmed up.
  26.  



Click image to see an enlarged view

Fig. Fig. 5: If it is easier, tag and disconnect the spark plug wires before removing the distributor cap



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Fig. Fig. 6: Disengage the wiring from the ignition coil



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Fig. Fig. 7: On 2.8L engines, there are usually 2 coil connectors (a small one which engages the top of the larger one)



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Fig. Fig. 8: Matchmark and remove the distributor from the rear of the intake manifold



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Fig. Fig. 9: Tag and disconnect all necessary vacuum connections, in this case the power brake booster



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Fig. Fig. 10: Remove the coolant hose from the thermostat housing water outlet



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Fig. Fig. 11: Remove the coolant hose from the front of the intake



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Fig. Fig. 12: When all wires, hoses and lines are disconnected from the manifold, it is ready for removal



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Fig. Fig. 13: If difficulty is encountered, make sure all bolts are removed, then use a prybar to help break the seal



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Fig. Fig. 14: Carefully lift the manifold assembly from the engine



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Fig. Fig. 15: Remove the old intake manifold gaskets from the block and cylinder heads



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Fig. Fig. 16: Remove all gasket material, BE careful not to damage the surface (and keep debris out of the engine)

4.3L Engine
VIN Z ENGINE, EXCEPT MFI-TURBO

See Figures 17 and 18



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Fig. Fig. 17: Intake manifold torque sequence-4.3L (VIN Z) engine, except MFI-turbo



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Fig. Fig. 18: Intake manifold mounting-4.3L (VIN Z) engine, except MFI-turbo; note the bolt/stud usage may vary

  1. Disconnect the negative battery cable and properly relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air cleaner and heat stove tube.
  6.  
  7. Remove the two braces at the rear of the serpentine drive belt tensioner.
  8.  
  9. Disconnect the upper radiator hose.
  10.  
  11. Remove the emissions relays along with the bracket, then disconnect the wiring harness from the retaining clips and position aside. Disconnect the ground cable from the intake manifold stud.
  12.  
  13. Remove the power brake vacuum pipe, then disconnect the heater hose pipe at the manifold and fuel lines at the TBI unit.
  14.  
  15. Remove the ignition coil, then disengage the electrical connectors at the sensors on the manifold.
  16.  
  17. Matchmark and remove the distributor from the engine. For details, please refer to the procedure earlier in this section.
  18.  

For ease of installation, DO NOT crank the engine with the distributor removed.

  1. Tag and disengage the wires and hoses from the TBI unit.
  2.  
  3. Disconnect the the EGR hose, then disconnect the throttle, TVS and cruise control cables (as equipped).
  4.  
  5. Remove the intake manifold retaining studs and/or bolts, then remove the manifold and gaskets.
  6.  

To install:
  1. Using a putty knife, carefully clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks; if necessary, replace it.
  2.  
  3. Position the gaskets to the cylinder head with the port blocking plates to the rear, then apply a 3 / 16 in. (5mm) bead of RTV sealant to the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.
  4.  
  5. Install the intake manifold taking care not to disturb the gaskets, then tighten the manifold retainers to 35 ft. lbs. (48 Nm) using the proper torque sequence.
  6.  
  7. Engage the TVS, cruise control and/or throttle cables, as equipped.
  8.  
  9. Connect the EGR hose then engage the wires and hoses at the TBI unit as noted during removal
  10.  
  11. Align and install the distributor assembly.
  12.  
  13. Install the ignition coil, then connect the fuel pipes.
  14.  
  15. Connect the heater hose pipe and the power brake vacuum pipe.
  16.  
  17. Connect the ground cable to the intake manifold stud, then position and secure the wiring harness using the clips.
  18.  
  19. Install the emissions relays along with their bracket, then connect the upper radiator hose.
  20.  
  21. Install the brace at the rear of the drive belt tensioner, then install the air cleaner and heat stove tube.
  22.  
  23. Connect the negative battery cable, then properly refill the engine cooling system.
  24.  
  25. Run the engine and check for leaks.
  26.  

VIN Z MFI-TURBO ENGINE

See Figures 19 and 20

  1. Properly relive the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system and the charge air cooling system.
  4.  
  5. Loosen the wing nut at the air cleaner, then position the air cleaner and duct aside.
  6.  
  7. Loosen the charge air cooler clamps, then remove the ducts and hoses.
  8.  
  9. Remove the charge air cooler from the supports, then remove the air cooler lateral (center) support.
  10.  
  11. Disengage the electrical connectors and hoses from the EVRV solenoid, the ignition coil and the MAP sensor located on the multi-use bracket.
  12.  
  13. Remove the multi-use bracket from the lower intake manifold assembly.
  14.  
  15. Tag and disengage the hoses and electrical connectors from the upper intake manifold assembly.
  16.  
  17. Loosen the throttle body retaining bolts, then remove the throttle body, gasket and cable bracket from the upper intake manifold.
  18.  



Click image to see an enlarged view

Fig. Fig. 19: Upper intake manifold components-4.3L MFI-turbo engine



Click image to see an enlarged view

Fig. Fig. 20: Upper intake manifold mounting-4.3L MFI-turbo engine

  1. Remove the upper intake manifold retaining bolts, then remove the manifold and gasket.
  2.  
  3. Disconnect the heater hose from the lower intake manifold.
  4.  
  5. Remove the charge air cooler coolant inlet pipe from the lower intake manifold, then disconnect it from the radiator by loosening the clamp and disengaging the hose.
  6.  
  7. Tag and disengage the wiring connectors from the fuel injectors, then disconnect the fuel pipes from the fuel rail assembly.
  8.  
  9. Loosen and remove the retaining bolts, then remove the fuel rail assembly (rail and injectors) from the lower manifold.
  10.  
  11. If equipped, remove the rear A/C brace,.
  12.  
  13. Disconnect the turbocharger coolant return line, then remove the upper radiator hose from the lower intake manifold.
  14.  
  15. Remove the ground strap from the lower intake manifold, then disengage the coolant sensor connector.
  16.  
  17. Tag and disconnect the spark plug wires from the distributor, remove the distributor cap and remove the distributor from the engine. Be sure to matchmark the distributor and rotor with the engine before removal.
  18.  
  19. Remove the lower intake manifold bolts and studs, then remove the manifold from the engine.
  20.  

To install:
  1. Using a putty knife, carefully clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks; if necessary, replace it.
  2.  
  3. Position the gaskets to the cylinder head with the port blocking plates to the rear, then apply a 3 / 16 in. (5mm) bead of RTV sealant to the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.
  4.  
  5. Install the lower intake manifold taking care not to disturb the gaskets, then tighten the manifold retainers to 35 ft. lbs. (48 Nm).
  6.  
  7. Align the marks made during removal and install the distributor to the engine. Install the distributor cap and engage the spark plug wires.
  8.  
  9. Engage the coolant sensor electrical connector, then connect the ground strap.
  10.  
  11. Connect the upper radiator hose and the turbocharger coolant return line, then install the A/C compressor rear brace (if equipped).
  12.  
  13. Install the fuel rail and injectors, then connect the fuel pipes to the rail and engage the wiring connectors to the injectors. Tighten the fuel rail bolts to 58 inch lbs. (6.5 Nm) and the pipe fittings to 16 ft. lbs. (22 Nm).
  14.  
  15. Place the charge air cooler coolant inlet pipe into position on the lower intake manifold, then connect the hose and clamp from the radiator to the charge air cooler inlet pipe.
  16.  
  17. Connect the heater hose to the lower intake manifold.
  18.  
  19. Install the upper intake manifold using a new gasket, then tighten the retaining bolts (starting from the 2 middle bolts working outward to each side) to 18 ft. lbs. (24 Nm).
  20.  
  21. Install the throttle body and cable bracket using a new throttle body gasket, then tighten the retaining bolts to 18 ft. lbs. (24 Nm).
  22.  
  23. Engage the upper intake manifold connectors and hoses, then install the multi-use bracket. Engage the hoses and wiring to the MAP sensor, ignition coil and EVRV solenoid.
  24.  
  25. Install the charge air cooler lateral support and finger-tighten the retaining nut.
  26.  
  27. Install and secure the charge air cooler supports, then tighten the lateral support nut.
  28.  
  29. Install the charge air cooler hoses and ducts, then secure using the clamps.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Properly refill the charge air cooling system and the engine cooling system.
  34.  

VIN W ENGINE

See Figures 21, 22 and 23

If only the upper intake manifold is being removed, the fuel system pressure does not need to be released. ALWAYS release the pressure before disconnecting any fuel lines.

  1. Remove the plastic cover, then properly relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system, then remove the air cleaner and air inlet duct.
  4.  
  5. Disengage the wiring harness from the necessary upper intake components including:

    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Intake Manifold Tuning Valve (IMTV)
     

  6.  
  7. Disengage the throttle linkage from the upper intake manifold, then remove the ignition coil.
  8.  
  9. Disconnect the PCV hose at the rear of the upper intake manifold, then tag and disengage the vacuum hoses from both the front and rear of the upper intake.
  10.  
  11. Remove the upper intake manifold bolts and studs, making sure to note or mark the location of all studs to assure proper installation. Remove the upper intake manifold from the engine.
  12.  
  13. Disengage the distributor wiring and matchmark the distributor, then remove the assembly from the engine.
  14.  
  15. Disconnect the upper radiator hose at the thermostat housing and the heater hose at the lower intake manifold.
  16.  
  17. Disconnect the fuel supply and return lines at the rear of the lower intake manifold.
  18.  
  19. Remove the pencil brace (A/C compressor bracket-to-lower intake manifold).
  20.  
  21. Disengage the wiring harness connectors from the necessary lower intake components including:

    Fuel injector
     
    Exhaust Gas Recirculation (EGR) valve
     
    Engine Coolant Temperature (ECT) sensor
     

  22.  
  23. Remove the lower intake manifold retaining bolts, then remove the manifold from the engine.
  24.  



Click image to see an enlarged view

Fig. Fig. 21: Exploded view of the intake manifold assembly-4.3L VIN Z engine



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Fig. Fig. 22: Lower intake manifold torque sequence-4.3L VIN Z engine



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Fig. Fig. 23: Upper intake manifold torque sequence-4.3L VIN Z engine

  1. Using a putty knife, carefully clean the gasket mounting surfaces. Be sure to inspect the manifold for warpage and/or cracks; if necessary, replace it.
  2.  
  3. Position the gaskets to the cylinder head with the port blocking plates to the rear and the "this side up'' stamps facing upward, then apply a 3 / 16 in. (5mm) bead of RTV sealant to the front and rear of the engine block at the block-to-manifold mating surface. Extend the bead 1 / 2 in. (13mm) up each cylinder head to seal and retain the gaskets.
  4.  
  5. Install the lower intake manifold taking care not to disturb the gaskets, then tighten the manifold retainers to 35 ft. lbs. (48 Nm) using the proper torque sequence.
  6.  
  7. Engage the wiring harness to the lower manifold components, including the injector, EGR valve and ECT sensor.
  8.  
  9. Install the pencil brace to the A/C compressor bracket and the lower intake manifold.
  10.  
  11. Connect the fuel supply and return lines to the rear of the lower intake. Temporarily reconnect the negative battery cable, then pressurize the fuel system (by cycling the ignition without starting the engine) and check for leaks. Disconnect the negative battery cable and continue installation.
  12.  
  13. Connect the heater hose to the lower intake and the upper radiator hose to the thermostat housing.
  14.  
  15. Align the matchmarks and install the distributor assembly, then engage the wiring.
  16.  
  17. Position a new upper intake manifold gasket on the engine, making sure the green sealing lines are facing upward.
  18.  
  19. Install the upper intake manifold being careful not to pinch the fuel injector wires between the manifolds.
  20.  
  21. Install the manifold retainers, making sure the studs are properly positioned, then tighten them using the proper sequence to 124 inch lbs. (14 Nm).
  22.  
  23. Connect the PCV hose to the rear of the upper intake manifold and the vacuum hoses to both the front and rear of the manifold assembly.
  24.  
  25. Connect the throttle linkage to the upper intake, then install the ignition coil.
  26.  
  27. Engage the necessary wiring to the upper intake components including the TP sensor, IAC motor, MAP sensor and the IMTV.
  28.  
  29. Install the plastic cover, the air cleaner and air inlet duct.
  30.  
  31. Connect the negative battery cable, then properly refill the engine cooling system.
  32.  

 
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