Chevrolet 17095069 Manifold Assembly, Upper Intake (W/ Throttle Body)

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Follow similar steps starting from removing the upper fan shroud, air cleaner assembly, draining the cooling system, and disconnecting the upper radiator and heater hoses. Unbolt the EGR valve, move heater hoses, and remove the ignition coil. Remove the small brace from the air conditioning compressor to the intake manifold and turn the engine to TDC for number 1 piston before removing the distributor.

Before accessing the intake manifold, you need to remove the air intake duct assembly, the PCV valve, hose connecting the intake manifold to the valve cover, and, in 1997 and earlier MFI models, the upper intake manifold.

To remove and install the intake manifold on various models, begin by disconnecting the negative battery cable. For 1994 and 1995 VIN Z models, remove the upper fan shroud, air cleaner assembly, drain the cooling system, and disconnect the upper radiator and heater hoses. Remove the two rear braces from the drive belt tensioner, unbolt the emission relays bracket, and proceed to remove the spark plug wires, coil, and distributor, marking the distributor rotor's relationship before removal. Disconnect the fuel lines at the TBI unit, remove accelerator, cruise control, and TV cables from the manifold, detach the vacuum brake booster pipe, and label and disconnect various lines and wires at the manifold and TBI unit. Move the EGR hose and begin loosening the manifold mounting bolts, followed by prying up the front of the manifold after removing all bolts. For 1996 and later models, follow similar steps starting from removing the upper fan shroud, air cleaner assembly, draining the cooling system, and disconnecting the upper radiator and heater hoses. Unbolt the EGR valve, move heater hoses, and remove the ignition coil. Remove the small brace from the air conditioning compressor to the intake manifold and turn the engine to TDC for number 1 piston before removing the distributor. When reinstalling, ensure clean mating surfaces by removing old gasket material and applying RTV sealant as needed. Install new intake manifold gaskets, making sure they align correctly, and set the manifold in place while the sealant is wet. Tighten the manifold bolts in the recommended sequence, then proceed with the remaining installation steps in reverse order, starting the engine and checking for leaks.

Before installing the manifold, you should clean the cylinder head and manifold gasket surfaces and apply a thin coat of RTV sealant to the intake manifold and cylinder head mating surfaces.

You should remove the spark plug wires from the coil pack, mark them for reassembly, and pull them up through the intake manifold, laying them over the left side of the engine.

Remove the two rear braces from the drive belt tensioner, unbolt the emission relays bracket, and proceed to remove the spark plug wires, coil, and distributor, marking the distributor rotor's relationship before removal. Disconnect the fuel lines at the TBI unit, remove accelerator, cruise control, and TV cables from the manifold, detach the vacuum brake booster pipe, and label and disconnect various lines and wires at the manifold and TBI unit. Move the EGR hose and begin loosening the manifold mounting bolts, followed by prying up the front of the manifold after removing all bolts.

Remove the two rear braces from the drive belt tensioner, unbolt the emission relays bracket, and proceed to remove the spark plug wires, coil, and distributor, marking the distributor rotor's relationship before removal. Disconnect the fuel lines at the TBI unit, remove accelerator, cruise control, and TV cables from the manifold, detach the vacuum brake booster pipe, and label and disconnect various lines and wires at the manifold and TBI unit. Move the EGR hose and begin loosening the manifold mounting bolts, followed by prying up the front of the manifold after removing all bolts.

Before separating the manifold from the cylinder head, you should remove the bolt holding the heater hose tube to the right rear of the manifold.