Installing a New Intake and Gaskets

Disclaimer: We can not accept any responsibility for anything that goes wrong or missed procedures on your job; use common sense and a good manual if you have never completed this before

The first few steps are simple and can be overlooked. Make sure you check everything before pulling on or unbolting the intake to avoid a large headache. This image depicts an intake before being disassembled.

1. Undo the ground cable.
2. Remove the cap from the distributor, keeping the wires attached to leave room to work.
3. Remove the intake hose between the throttle body and Air/Fuel Meter.
4. Undo wiring harness clamp, and remove all intake wiring, be careful to not break any of the brittle clips.
5. Remove all vacuum hoses from surrounding parts. (Brake booster, PCV valve, etc.)
6. Drain about a gallon of coolant.
7. Remove air bypass valve and hoses, and EGR control.
8. Remove throttle rod, remove hair pin and arm will slide out.
9. Remove pulley from front of engine, power steering belt must be loosened first, no need to remove mechanical fan.
10. Remove coolant line running to EGR control from above lower radiator hose.
11. Disconnect fuel lines, to relieve pressure, touch power + ground to cold start valve, as per factory manual.
12. Remove EGR tube from intake side because it’s usually not seized like the manifold side.
13. Disconnect exhaust from header pipe, or at manifold flange, or catalytic converter, whichever is easier and not going to break, use PB blaster or similar penetrating oil.
14. Remove EGR valve (if equipped) and then the heat shield 12mm bolts.
15. Remove access plate on top of intake, to reveal top exhaust bolt.
16. Start to undo all 12mm bolts off of exhaust under to intake, do not undo the 2 end bolts on the ends of exhaust or the 3 center bolts, they do not need to be removed to remove intake. For this step use a wrench, long extension, mirror, and flashlight, whatever it takes to get these nuts off.
17. Use a very long extension with swivel and 14mm socket and remove all 4 bolts from intake, then remove the intake.
18. Remove final 5 bolts and remove header.
19. Clean all surfaces with scraper, if using a power disk, do not make any imperfections in surfaces, this could cause future leakage.
20. Installation is reverse of removal. To install intake easier, install all nuts and washers loosely on sections where intake and exhaust share so you don’t have to try and get your hand in there. Tighten all 5 nuts on the exhaust that were previously left until last.

Have fun and take your time. If it has been done before, it may only take 2 hours or so. If it’s your first time, allow some time if you break bolts or need other repairs. When putting everything back together, use some Never Seize. It will make everything easier for next time.

Sources used on this page:

• Written by: SHADY280 of ZDriver.com