To remove the components, first relieve the fuel system pressure, then disconnect the negative battery cable from the battery. Remove both rocker arm covers and drain the engine coolant. Disconnect and remove the intake hose between the throttle body and the elbow at the air cleaner canister, followed by removing the distributor cap and attached spark plug wires. Mark the position of the rotor and remove the distributor. Next, disconnect the shift linkage, throttle cable, downshift cable, and cruise control cable if applicable. Unbolt and remove the throttle body from the upper plenum, then disconnect the radiator hose and fill inlet. Disconnect the inlet and return heater hose and pipe from the throttle body, along with the wiring harness, labeling all wires for reinstallation. Disconnect the heater hoses and all vacuum hoses, labeling them for correct installation. Remove the brake booster pipe and bracket, the EGR pipe, and the upper manifold plenum along with the old gaskets. Disconnect the fuel line inlet and return fittings at the fuel block, then disconnect the wires from the fuel injectors. Remove the intermediate intake manifold and old gasket, noting that the intermediate intake manifold, fuel rail, and injectors can be removed as an assembly, followed by the lower intake manifold and old gaskets. For installation, clean the gasket surfaces on the cylinder head and intake manifolds, applying a smooth, continuous bead of sealant to the front and rear mating surfaces of the lower intake manifold and the top of the block, ensuring the surface is free of oil and dirt. Place the lower intake manifold and gasket in position, tightening all bolts in the proper sequence to the specified torque, then do the same for the intermediate intake manifold and gasket. Connect the wires to the injectors and the fuel line fittings to the fuel metering block, then place the upper manifold plenum and gaskets in position, tightening all bolts in the proper sequence to the specified torque. Bolt the throttle body to the upper plenum, install the EGR pipe, and the brake booster pipe and bracket. Reattach all vacuum hoses and heater hoses, reconnect the wiring harness, install the radiator fill inlet, and reattach the radiator hose. Reconnect the inlet and return heater hose and pipe to the throttle body, hook up the shift linkage, throttle cable, downshift cable, and cruise control cable, then install the distributor. Reattach the intake hose between the throttle body and the elbow at the air cleaner, tightening the hose clamps securely. Fill the engine with coolant, install both rocker arm covers, and finally, reattach the negative battery cable, checking the ignition timing and coolant level while looking for fluid leaks.
