How to Replace the Intake Manifold in a Chevy Corvette

Disconnect the negative battery cable and lift out the air cleaner assembly. Disconnect the fuel inlet and return line taking care not to spill fuel. Label and then remove the necessary vacuum lines.

Label all the necessary electrical connections and disconnect them. Take out the cables for the accelerator, cruise control and detent. Take the cable from the accelerator bracket.

Remove the nuts and bolts from the intake cover then lift off the cover. Drain the cooling system (see Warnings). Take the radiator hose from the thermostat outlet.

Lift off the distributor cap, put a matchmark position on the distributor and remove it. Disconnect the heater hose from the rear of the intake manifold. Remove the accessory drive belt.

Continue removing the necessary items to access and remove the intake manifold, including the AIR pump pulley and valve adapter, the mounting bolts and the pump itself.

Detach the coolant temperature sensor. Loosen the intake manifold bolts then lift the manifold from the engine.

Remove the gaskets and discard them. Clean the mating surfaces thoroughly with solvent and dry them. Inspect them for damage.

Place the gaskets on the head with the blocked openings positioned to the rear of the engine. Bend the gasket tab flush with the cylinder head. Apply a 3/16 inch bead of RTV sealant to the front and rear ridges of the cylinder case.

Use Loctite 1052624 or a similar product to coat the manifold mounting bolts. Install the manifold, put the bolts in place and then tighten in sequence, using three passes to torque the bolts to 35 foot pounds.

Reconnect or install the engine components in reverse order of their removal. Tighten the intake cover and then reconnect the negative battery cable. Fill the cooling system with the proper type and amount of coolant.

Start the engine. Check for vacuum or fuel leaks.