Disconnect and tag all wires, harnesses, coolant and vacuum hoses from the
intake manifold.
Disconnect the shift and accelerator cables.
Remove the fuel pipes.
Remove the distributor and EGR valve.
Remove the PCV hose.
Remove the water outlet, by-pass pipe and gasket from the manifold.
Disconnect the water hose form the water pump and remove the bolt holding
the water by-pass pipe and timing chain case.
Remove the intake manifold stays.
Remove the 2 nuts and 4 bolts and extract the intake manifold with gasket.
Remove the cylinder block insulators.
Fig. 1: Intake manifold bolt and nut locations
To install:
Position the cylinder block insulator on the cylinder head.
Position a new gasket on the cylinder head and install the intake manifold
with the 2 nuts and 4 bolts. Tighten the fasteners to 15 ft. lbs. (21 Nm).
Use a crisscross pattern starting from the center and work outwards.
Install the intake manifold stays and secure to 27 ft. lbs. (37 Nm) to the
block and 13 ft. lbs. (18 Nm) to the intake manifold.
Install the bolt holding the water by-pass pipe and timing chain case and
tighten to 13 ft. lbs. (18 Nm). Connect the water hose to the water pump.
Install the delivery pipe, water outlet and EGR valve.
Install the distributor.
Connect all wires, connectors, coolant and vacuum hoses from the intake
manifold.
