How JustAnswer Works:

  • Ask an Expert
    Experts are full of valuable knowledge and are ready to help with any question. Credentials confirmed by a Fortune 500 verification firm.
  • Get a Professional Answer
    Via email, text message, or notification as you wait on our site.
    Ask follow up questions if you need to.
  • 100% Satisfaction Guarantee
    Rate the answer you receive.

Ask Eric Your Own Question

Eric
Eric, Automotive Repair Shop Manager
Category: Chevy
Satisfied Customers: 25178
Experience:  20+ yrs. experience as repair shop manager and technician.
3195632
Type Your Chevy Question Here...
Eric is online now
A new question is answered every 9 seconds

Replacing..intake manifold gaskets on 1996 5.7l vortec.

Resolved Question:

I need a step by step instruction for replacing intake manifold gaskets on 1996 5.7l vortec.
Submitted: 5 years ago.
Category: Chevy
Expert:  Eric replied 5 years ago.

Hi,

 

below are directions to replace intakes:

 

UPPER INTAKE:

 

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner intake duct.
  3. Remove the wiring harness connectors and brackets and move them aside.
  4. Disconnect the throttle linkage and bracket from the upper intake manifold.
  5. Remove the cruise control cable (if equipped).
  6. Remove the PCV valve and hose.
  7. Remove the fuel lines and bracket from the intake to the rear of the block.
  8. Remove the ignition coil and bracket.
  9. Remove the purge solenoid and bracket.

 

Note the location of the manifold bolts and studs before removal for reassembly in their original positions.

  1. Remove the intake manifold bolts and studs.

 

Do not disassemble the CSFI unit.

  1. Remove the upper intake manifold.


To install:

  1. Install the upper intake manifold gasket.
  2. Install the upper intake manifold.

 

When installing the upper intake manifold be careful not to pinch the injector wires between the upper and lower intake manifolds.

  1. Install the upper intake manifold mounting bolts and studs in the same locations as prior to removal.
  2. Tighten the bolts and studs in a crisscross pattern in 2 steps first to 45 inch lbs. (5 Nm) then to 83 inch lbs. (10 Nm).
  3. Install the purge solenoid and bracket.
  4. Install the ignition coil and bracket.
  5. Attach the PCV hose to the upper intake manifold.
  6. Attach the fuel lines and bracket at the rear of the block.
  7. Install the cruise control cable (if equipped).
  8. Install the throttle linkage and bracket to the upper intake manifold.
  9. Install the throttle linkage cable.
  10. Install the wiring harness connectors and brackets.
  11. Install the air cleaner intake duct.
  12. Connect the negative battery cable.
  13. Start the vehicle and verify no leaks.

 

LOWER INTAKE:

 

1996-98 MODELS

See Figure 10



Click image to see an enlarged view

Fig. Fig. 10: Intake manifold bolt tightening sequence-1996-98 5.0L and 5.7L engines

  1. Remove the upper intake manifold using the recommended procedure outlined in this section.
  2. Remove the distributor.
  3. Disconnect the upper radiator hose from the thermostat housing.
  4. Disconnect the heater hose from the lower intake manifold.
  5. Remove the coolant by-pass hose.
  6. Remove the EGR valve.
  7. Disconnect the fuel pressure and return lines from the lower intake manifold.
  8. Disconnect the wiring harnesses and brackets from the lower manifold.
  9. Disconnect the throttle cable, the cruise control cable (if equipped) and the bracket from the manifold.
  10. If necessary, remove the left side valve cover.
  11. Remove the transmission oil level indicator and tube, if equipped.
  12. Remove the EGR tube, clamp and bolt.
  13. Remove the PCV valve and vacuum hoses.
  14. Remove the A/C compressor and bracket, but do NOT disconnect the lines. Move the compressor out of the way. Take care not to kink the A/C lines.
  15. Loosen the compressor mounting bracket and slide it forward, but do NOT remove it.
  16. Remove the power brake vacuum tube.
  17. If necessary, remove the alternator rear bracket bolt.
  18. Remove the lower intake manifold bolts.
  19. Remove the lower intake manifold.


To install:

  1. Clean all gasket surfaces completely.
  2. Install the intake manifold gaskets with the port blocking plates facing the rear. Factory gaskets should have the words "This Side Up" visible.
  3. Apply gasket sealer to the front and rear sealing surfaces of the engine block.
  4. Apply a 0.197 inch (5mm) bead of RTV sealer to the front and rear of the block. Extend the sealer approximately 1 / 2 -inch (13mm) onto the heads.
  5. Install the lower intake manifold.
  6. Apply sealer to the lower intake manifold bolts prior to installation.
  7. Install the bolts and tighten in sequence and in 3 steps as follows:
    1. First step to 71 inch lbs. (8 Nm).
    2. Second step to 106 inch lbs. (12 Nm).
    3. Final step to 11 ft. lbs. (15 Nm).

  8. Connect the wiring harnesses and brackets to the lower manifold.
  9. Install the power brake vacuum tube.
  10. Install the PCV valve and hose.
  11. Install the EGR tube, clamp and bolt.
  12. Install the transmission oil level indicator and tube, if equipped.
  13. If removed, install the left side valve cover.
  14. Connect the fuel pressure and return lines to the lower intake manifold.
  15. Connect the wiring harnesses and brackets to the lower manifold.
  16. Install the throttle cable bracket, then attach the throttle cable and the cruise control cable (if equipped).
  17. Install the EGR valve.
  18. Install the coolant by-pass hose.
  19. Connect the heater hose to the lower intake manifold.
  20. Connect the upper radiator hose to the thermostat housing.
  21. If removed, install the alternator bracket bolt.
  22. Install the A/C compressor and bracket.
  23. Install the distributor.
  24. Connect the negative battery cable.
  25. Refill the cooling system.
  26. Start the vehicle and check the ignition timing (not adjustable).
  27. Verify no oil, coolant, vacuum or fuel leaks.
Eric, Automotive Repair Shop Manager
Category: Chevy
Satisfied Customers: 25178
Experience: 20+ yrs. experience as repair shop manager and technician.
Eric and 7 other Chevy Specialists are ready to help you

JustAnswer in the News:

 
 
 
Ask-a-doc Web sites: If you've got a quick question, you can try to get an answer from sites that say they have various specialists on hand to give quick answers... Justanswer.com.
JustAnswer.com...has seen a spike since October in legal questions from readers about layoffs, unemployment and severance.
Web sites like justanswer.com/legal
...leave nothing to chance.
Traffic on JustAnswer rose 14 percent...and had nearly 400,000 page views in 30 days...inquiries related to stress, high blood pressure, drinking and heart pain jumped 33 percent.
Tory Johnson, GMA Workplace Contributor, discusses work-from-home jobs, such as JustAnswer in which verified Experts answer people’s questions.
I will tell you that...the things you have to go through to be an Expert are quite rigorous.
 
 
 

What Customers are Saying:

 
 
 
  • I was having a terrible problem with the wheel bearings on my 98 Chevy Cavalier and I suspect that using this website saved me plenty of time and money. Todd L Rochester NY
< Last | Next >
  • I was having a terrible problem with the wheel bearings on my 98 Chevy Cavalier and I suspect that using this website saved me plenty of time and money. Todd L Rochester NY
  • Wonderful service, prompt, efficient, and accurate. Couldn't have asked for more. I cannot thank you enough for your help. Mary C. Freshfield, Liverpool, UK
  • This expert is wonderful. They truly know what they are talking about, and they actually care about you. They really helped put my nerves at ease. Thank you so much!!!! Alex Los Angeles, CA
  • Thank you for all your help. It is nice to know that this service is here for people like myself, who need answers fast and are not sure who to consult. GP Hesperia, CA
  • I couldn't be more satisfied! This is the site I will always come to when I need a second opinion. Justin Kernersville, NC
  • Just let me say that this encounter has been entirely professional and most helpful. I liked that I could ask additional questions and get answered in a very short turn around. Esther Woodstock, NY
  • Thank you so much for taking your time and knowledge to support my concerns. Not only did you answer my questions, you even took it a step further with replying with more pertinent information I needed to know. Robin Elkton, Maryland
 
 
 

Meet The Experts:

 
 
 
  • Tim's Auto Repair

    mechanic

    Satisfied Customers:

    7641
    Have owned a repair shop for 25 yrs.
< Last | Next >
  • http://ww2.justanswer.com/uploads/TI/tim37857/2011-10-28_23053_S6301814.64x64.JPG Tim's Auto Repair's Avatar

    Tim's Auto Repair

    mechanic

    Satisfied Customers:

    7641
    Have owned a repair shop for 25 yrs.
  • http://ww2.justanswer.com/uploads/DT/dt69nova/2012-6-15_234154_pic1.64x64.jpg Dave Nova's Avatar

    Dave Nova

    Chevrolet Technician

    Satisfied Customers:

    6870
    ASE Master Certification. GM World Class Certification
  • http://ww2.justanswer.com/uploads/ggrote1/2009-06-27_031011_me.jpg Gary's Avatar

    Gary

    Chevy Technician

    Satisfied Customers:

    5404
    15 years GM master tech
  • http://ww2.justanswer.com/uploads/testedtuff/2009-09-26_170108_pictures.jpg John's Avatar

    John

    Master A.S.E Automotive technician

    Satisfied Customers:

    4071
    A.S.E MasterTechnician A1-A8 w/L1,38 years experience General Motors Master Technician
  • http://ww2.justanswer.com/uploads/RO/rodcuda/2011-7-25_224114_Donhoff1.64x64.JPG Neal's Avatar

    Neal

    Chevy Mechanic

    Satisfied Customers:

    2306
    Shop Owner and Mechanic on multiple makes.
  • http://ww2.justanswer.com/uploads/goodwrench9124/2008-11-09_220838_dscf0007.jpg goodwrench9124's Avatar

    goodwrench9124

    ASE Certified Technician

    Satisfied Customers:

    2041
    Ase Master Certified, GM Master Certified Tech. Awarded GM Top performer, Hybrid certified
  • http://ww2.justanswer.com/uploads/DR/drivefast1971/2012-1-12_172422_0009051tQKh.64x64.jpg Ron Z.'s Avatar

    Ron Z.

    - Chevy Tech -

    Satisfied Customers:

    1912
    18+yrs experience. State Inspector and Chevy Diagnostics
 
 
 
Chat Now With A Chevy Mechanic
Eric
Eric
Retired
2291 Satisfied Customers
20+ yrs. experience as repair shop manager and technician.