GM 10031385 Manifold Asm,Intake

Specific steps and precautions must be followed for the removal and installation of intake manifolds on various engine types. For 196, 231, 252, and 350 Buick Engines, disconnect the negative battery cable. Drain the radiator. Remove air cleaner. Disconnect the upper radiator hose and heater hose at manifold. Disconnect other linkages and brackets like accelerator linkage and bracket, cruise control chain (if applicable), fuel line, booster vacuum pipe etc.On 1976 models, remove choke pipe from choke housing; label wire, hoses and bracket as necessary; On six-cylinder models, distributor cap and wires may need to be removed to access a Torx® head bolt. Also remove throttle linkage springs as necessary ,then remove manifold itself. This entails using a new gasket with sealer on the rubber gasket seals ,ensure proper alignment,and tightening bolts in specified order for installation purposes. For 305 and 350 Chevrolet Engines: Drain cooling system. Take off air cleaner assembly. Rmove battery ground,Then Upper radiator hose and heater hose from manifold , Then disconnect all linkages such as hoses associated with carburetor/manifold assembly,and then distributor after marking rotor position,.remove any other brackets or springs,Before unbolting it and removing it from the vehicle or engine so you can comprehend this better.,To install it back use old gaskets in opposite order while ensuring proper torque sequence is followed by bolts of the manifold will secure it tightly enough in place again . For 350 And 403 Oldsmobile Gasoline Engines: take off carburetor air cleaner first then drain radiator right away to prevent overheating,. Remove connecting upper radiator hose/bypass hose/heater hose To do this you might want to consider removing throttle linkage,vacuum & gas lines that are connected to carburetor , generator related brackets ,as well as some air conditioning parts . Then disconnect temperature gauge wire; EGR solenoid assembly, Idle Load Compensator unit and similar components. Also remove the EGR valve before taking off the intake manifold itself. Finally, clean gaskets surfaces, apply sealer, place gaskets,and secure manifold bolts in a certain sequence. For 307 Oldsmobile Gasoline Engines: take off carburetor air cleaner first then drain radiator right away to prevent overheating,. Disconnect all hoses such as upper radiator hose/bypass hose/heater hose Then, you should disconnected other things like throttle linkage,vacuum lines and gas lines. Besides, brackets related to generator/air conditioning could have been removed if necessary. As for electrical leads , they are disconnected after which components like the EGR solenoid assembly and Idle Load Compensator (ILC) are taken out . Take off the EGR valve then unfasten and take out the intake manifold bolts . In conclusion, clean gasket surfaces well using a suitable sealer. After that install all these manifolds' gaskets again properly into position while tightening their bolts in specific order only. For 265 And 301 Pontiac Engines: It is not necessary to follow a specific torque sequence during this process. Remove EGA valves except in 301 Remove intake manifold bolts after removing distributor, Drain radiator/block and remove various hoses plus brackets etc,Then you can pull out the intake manifold fast enough after unbolting it from an engine block. After that lay down new gaskets accordingly on both its sides, followed by applying sealer on them and finally fix up such with their corresponding bolts tightly. For 263 And 350 Oldsmobile Diesel Engines: take out air cleaner as well as draining radiator immediately Do so by simply undoing some hoses , brackets or even components like fuel injection pump along with its lines, vacuum pump or oil pump drive assembly ,Remove also any other hardware including intake manifold bolts which when undone will lead to it coming out of the engine. Apply sealer, place gaskets and secure the manifold bolts ensuring that as well as reinstalling all removed components in reverse order.

If the engine has been removed from the car, disregard the following steps which do not apply. First, if the vehicle is equipped with air conditioning, carefully examine the routing of the A/C hoses and the mounting of the compressor, as it may be possible to remove the intake manifold without disconnecting the A/C system; if in doubt, consult a certified dealer or refrigeration specialist to have the system depressurized, and do not disconnect the A/C hoses while the system is under pressure. Next, disconnect the negative battery cable and drain the coolant from the radiator. Remove the air cleaner assembly, noting the position of all hoses and pipes, then disconnect the upper radiator hose and the heater hose from the intake manifold. Disconnect the accelerator linkage at the carburetor, ensuring any supporting bracket on the manifold is also removed. With a container handy to catch any spillage, disconnect the fuel inlet hose at the carburetor, plugging the end to prevent dirt from entering the system and excessive fuel seepage. Disconnect all other hoses connected to the carburetor, identifying each hose with strips of numbered tape to prevent confusion upon reassembly. Remove the distributor, ensuring the distributor cap with spark plug wires is taped or wired out of the way, and then remove both rocker arm covers. Disconnect the vacuum hose leading to the power brake booster if equipped, and remove any accessory brackets attached to the intake manifold. Remove the external EFE pipe from the rear of the manifold, followed by the intake manifold-to-cylinder head attaching bolts. Lift the manifold, complete with carburetor, free from the engine without prying on the mating surfaces to avoid damage. If replacing the intake manifold, transfer all components that have not yet been removed, including the carburetor and its attaching bolts or studs, temperature or oil pressure sending unit, heater hose and water pump hose adapter fittings, EGR valve with a new gasket, emission system TV switches, and carburetor choke assembly. Before installing the manifold, place clean lint-free rags in the engine cavity and thoroughly clean the engine block, cylinder heads, and manifold gasket surfaces, ensuring all extra gasket material and sealing compound are removed. Clean the sealing surfaces of the cylinder case's front and rear ridges with degreaser, then apply a 3/16 in (5 mm) diameter bead of RTV or equivalent sealant on each ridge. Install the new intake gaskets on the cylinder heads, ensuring the correct gasket is used for each head, and hold the gaskets in place by extending the bead of RTV onto the gasket ends. Carefully lower the intake manifold into position, ensuring the gaskets are not disturbed, then install the intake manifold mounting bolts and tighten them in sequence, gradually torquing them to specifications. Finally, install the remaining components in the reverse order of removal, fill the radiator with coolant, start the engine, check for leaks, and adjust the ignition timing and carburetor idle speeds as necessary.

If the engine has been removed from the car, disregard the following steps which do not apply. First, if the vehicle is equipped with air conditioning, carefully examine the routing of the A/C hoses and the mounting of the compressor, as it may be possible to remove the intake manifold without disconnecting the A/C system; if in doubt, consult a certified dealer or refrigeration specialist to have the system depressurized, and do not disconnect the A/C hoses while the system is under pressure. Next, disconnect the negative battery cable and drain the coolant from the radiator. Remove the air cleaner assembly, noting the position of all hoses and pipes, then disconnect the upper radiator hose and the heater hose from the intake manifold. Disconnect the accelerator linkage at the carburetor, ensuring any supporting bracket on the manifold is also removed. With a container handy to catch any spillage, disconnect the fuel inlet hose at the carburetor, plugging the end to prevent dirt from entering the system and excessive fuel seepage. Disconnect all other hoses connected to the carburetor, identifying each hose with strips of numbered tape to prevent confusion upon reassembly. Remove the distributor, ensuring the distributor cap with spark plug wires is taped or wired out of the way, and then remove both rocker arm covers. Disconnect the vacuum hose leading to the power brake booster if equipped, and remove any accessory brackets attached to the intake manifold. Remove the external EFE pipe from the rear of the manifold, followed by the intake manifold-to-cylinder head attaching bolts. Lift the manifold, complete with carburetor, free from the engine without prying on the mating surfaces to avoid damage. If replacing the intake manifold, transfer all components that have not yet been removed, including the carburetor and its attaching bolts or studs, temperature or oil pressure sending unit, heater hose and water pump hose adapter fittings, EGR valve with a new gasket, emission system TV switches, and carburetor choke assembly. Before installing the manifold, place clean lint-free rags in the engine cavity and thoroughly clean the engine block, cylinder heads, and manifold gasket surfaces, ensuring all extra gasket material and sealing compound are removed. Clean the sealing surfaces of the cylinder case's front and rear ridges with degreaser, then apply a 3/16 in (5 mm) diameter bead of RTV or equivalent sealant on each ridge. Install the new intake gaskets on the cylinder heads, ensuring the correct gasket is used for each head, and hold the gaskets in place by extending the bead of RTV onto the gasket ends. Carefully lower the intake manifold into position, ensuring the gaskets are not disturbed, then install the intake manifold mounting bolts and tighten them in sequence, gradually torquing them to specifications. Finally, install the remaining components in the reverse order of removal, fill the radiator with coolant, start the engine, check for leaks, and adjust the ignition timing and carburetor idle speeds as necessary.

To remove the components, first disconnect the cable from the negative battery terminal and remove the air cleaner assembly, tagging each hose with numbered or colored tape for easier installation. Relieve the fuel pressure and drain the cooling system. Remove the PCV valve and hose at the throttle body housing, then label and disconnect the fuel line fittings at the throttle body, removing the fuel filter bracket bolt underneath. Label and disconnect the vacuum lines and electrical leads from the fuel injection assembly. Disconnect the throttle cable from the throttle linkage by prying off the C-clip and popping off the linkage rod, noting its installation. If equipped with an automatic transmission, disconnect and remove the transaxle downshift linkage, and if cruise control is present, disconnect the linkage. Disconnect the heater hose fitting located on the underside of the intake manifold. Remove the forward strut rod through-bolt adjacent to the cylinder head, then remove the access plate in the top of the right fender well to access and remove the rear through-bolt, followed by the strut rod. Disconnect the alternator by removing the belt tensioning nut and bolt, then remove the alternator bracket. Disconnect the coil mounting nuts, coil lead, and coil wire, then remove the coil. Remove the intake manifold mounting bolts and separate the manifold from the cylinder head without prying to avoid damaging the gasket sealing surfaces. Remove the intake manifold gasket with a gasket scraper, ensuring no material remains on the mating surface. For installation, if replacing the intake manifold, transfer all components from the old manifold to the new one. Clean the cylinder head and manifold gasket surfaces, ensuring all gasket material and sealing compound are removed. Place a new intake manifold gasket on the manifold, hold it against the cylinder head, and install the mounting bolts finger tight. Tighten the mounting bolts gradually in the proper sequence to the specified torque, then push the electrical connectors back through the intake manifold. Install the alternator bracket, adjust the alternator belt tension, and install the strut rod with both through-bolts, tightening them to the specified torque before replacing the fender well through-bolt access plate. Place the TBI linkage rod into position and reattach the throttle cable, then reattach the heater hose fitting to the underside of the intake manifold. Reconnect the fuel feed and return lines, installing the fuel filter bracket mounting bolt, and reattach the PCV valve, elbow, and hose between the rocker arm cover and the TBI housing. Reattach the remaining vacuum lines and electrical connectors, install the coil assembly, and reconnect the coil lead and coil wire. Finally, install the air cleaner, fill the radiator with coolant, start the engine, and check for leaks.

Pull out the air cleaner and make notations on the lines and hoses as to their location; next, pull out the PCV hose and lastly, remove the negative battery terminal. Siphon the cooling system and dismount the carbureter or throttle body body put together with its base gasket. Remove the vacuum lines from the carburetor spacer and then unscrew the EGA valve, and then the carburetor spacer along with its gasket. There will also be removal of the bell crank and throttle linkage brackets to avail room, and modification of the heater hose from the intake manifold as well as the upper generator bracket. If fitted, remove the PULSAIR air valve bracket, then the intake manifold to cylinder head bolts and the manifold along with the gasket. Incase you are integrating the project of replacing the intake manifold, then ensure you transfer over all the remaining parts from the old one to the new one. Put unbleached cotton waste pads over the engine and if possible, clean all the sealing surfaces of the engine block with a lint free rag, the cylinder head and the manifold gasket surfaces properly removing all the gasket material and the sealing compound. Squash a thin line of RTV or equivalent sealer to the meeting surfaces, but do not intrude into the air or water channels. Place a new intake manifold gasket on the manifold, put the manifold on the cylinder head and tighten the mounting bolts only hand-tight. Loosening the bolts in a sequence until they reach the torque of the system recommended torque gradually. The last packages should be reinstalled, refilling of the radiator with coolant followed by running of the engine and realized that there is no leakage before adjustment of the carburetor for the idle speeds.

Remove the air cleaner, labeling the lines and hoses for their proper location.

For later models, removing the front manifold bolt will require removing the drive belt and the air conditioning compressor side brace, then loosening the nuts and bolts for the power steering pump mounting bracket.

Fuel is supplied by a high-pressure electric pump located in the fuel tank, and its pressure is regulated by a fuel pressure regulator.

Place a new gasket on the manifold, hold it in position against the cylinder head, and install the mounting bolts finger tight.

Disconnect all other hoses connected to the carburetor, identifying each with numbered tape to avoid confusion during reassembly.

Connect or re-install the components in the reverse order of removal, reconnect the battery cable, close the drain plug, and refill the cooling system.

Install the mounting bolts finger tight, then tighten them in sequence gradually until they reach the specified torque.

For carbureted models, remove the air cleaner assembly, tagging each disconnected hose with numbered tape for easier reinstallation. Then, label and disconnect all electrical wires and vacuum hoses at the carburetor, followed by disconnecting the fuel line and plugging it to prevent contamination.

Disconnect the fuel line inlet and return fittings at the fuel block, then disconnect the wires from the fuel injectors.

Clean the sealing surfaces thoroughly before installing new gaskets and RTV sealant. Lower the intake manifold into position, install the bolts, and tighten them in a criss-cross pattern before final tightening in the recommended sequence, completing the process by reversing the removal steps.

Disconnect the coil wire, remove the two retaining screws and one bolt, then take out the coil.

Disconnect all other hoses connected to the carburetor, identifying each hose with strips of numbered tape to prevent confusion upon reassembly.