Lower Intake Manifold R & I: Installation

Clean and oil manifold bolt threads. To install, reverse removal procedure, using new manifold gaskets. When installing injectors, see FUEL INJECTORS R & I  in this article. Tighten manifold bolts in correct order. See Fig 1 .

Fig 1: 2.3L Engine Lower Intake Manifold Tightening Sequence

1. Apply sealing compound to joining surfaces. Place intake manifold gasket into position. Ensure that tab on right bank cylinder head gasket fits into cut-out of manifold gasket. Apply sealing compound to attaching bolt bosses on intake manifold and position intake manifold. Tighten to specifications. See Fig 1 .
2. Install throttle body and plenum assembly. Install distributor so rotor and housing are in same position marked at removal. Install distributor clamp and attaching bolt. Connect distributor wire. Install fuel line.
3. Replace rocker arm cover gaskets and reinstall rocker arm valve covers. Install distributor cap. Coat inside of each spark plug wire connector with silicone grease with a small screwdriver, and install wires. Connect distributor wiring harness.
4. Install and adjust throttle linkage. Install air cleaner and air cleaner tube at carburetor. Connect battery negative cable. Connect hoses from water outlet to radiator and by-pass hose from thermostat housing rear cover to intake manifold.
5. Refill and bleed cooling system. Recheck ignition timing and reset engine idle speed to specifications. Run engine at fast idle and check for coolant and oil leaks.

Fig 1: 2.9L Engine Lower Intake Manifold Tightening Sequence