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11 - 10
EXHAUST SYSTEM AND INTAKE MANIFOLD
•
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cable.
(2) D r a i n t h e cooling system (refer t o Group 7,
Cooling System for t h e proper procedures).
(3) Remove the alternator, a i r cleaner a n d fuel
lines ( i n t a k e and r e t u r n ) .
(4) Disconnect t h e accelerator l i n k a g e a n d i f so
equipped, t h e speed control and transmission k i c k -
down cables.
(5) Remove the r e t u r n spring.
(6) Remove the d i s t r i b u t o r cap and wires.
(7) Disconnect the coil wires, heat i n d i c a t o r send-
i n g u n i t w i r e , heater hoses and bypass hose.
(8) Remove the closed crankcase v e n t i l a t i o n and
evaporation control systems.
(9) Remove the r i g h t cylinder head cover.
(10) Remove i n t a k e manifold bolts.
(11) L i f t the i n t a k e manifold and t h r o t t l e body out
of the engine compartment as a n assembly.
(12) Remove the t h r o t t l e body bolts a n d l i f t t h e
t h r o t t l e body off the i n t a k e manifold (Fig. 7). Discard
the t h r o t t l e body gasket.
BOLTS
J9011-31
Fig. 7 Throttle Body
Assembly
CLEANING
AND
INSPECTION
Clean manifold i n solvent and blow d r y w i t h com-
pressed a i r .
Inspect manifold for cracks.
Inspect m a t i n g surfaces of manifold f o r flatness
w i t h a straightedge.
Inspect exhaust crossover passages t h r o u g h m a n i -
fold. I f passages are coated w i t h hard, b l a c k carbon,
they should be scraped clean and sandblasted t o re-
move t h e carbon deposits.
INSTALLATION
(1) U s i n g a new gasket, i n s t a l l the t h r o t t l e body
onto t h e intake manifold. T i g h t e n t h e bolts t o 20
N T H (175 i n . lbs.) torque.
CAUTION: Intake manifold SIDE gaskets are identi-
fied with cutouts (RT for RIGHT side and LT for
LEFT side) (Figs. 8 and 9). They MUST be installed
as
designated to provide proper coolant flow
through the water cooled intake manifold.
Fig. 8 Intake Manifold Side Gaskets
(3.9L Left Side
Shown)
Fig. 9 Intake Manifold Side Gaskets
(5.2L Left Side
Shown)
(2) Place a drop (approximately 1/4 i n c h diameter)
of Rubber Sealer (RTV) into each of t h e four block to
cylinder head corners.
(3) A p p l y a t h i n , u n i f o r m coating of a q u i c k dry ce-
ment t o the i n t a k e manifold f r o n t and rear gaskets
and cylinder block gasket surface.
(4) A l l o w to dry 4 to 5 m i n u t e s or u n t i l tack-free to
the touch.
(5) Carefully i n s t a l l the front and rear i n t a k e man-
ifold gaskets. When i n s t a l l i n g gaskets, t h e center
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