96 Corsica Intake Manifold

REMOVE OR DISCONNECT

Relieve fuel system pressure.
Top half of the air cleaner assembly and throttle body duct.
Drain and recover cooling system.
EGR pipe from exhaust manifold.
Serpentine belt.
Brake vacuum pipe at plenum.
Power steering lines at generator bracket.
Generator.
Secondary ignition wires from spark plugs and harness at plenum.
Electronic ignition coil and module assembly and the EVAP canister purge solenoid at the same time.
Upper engine wiring harness connectors:
Throttle Position (TP) sensor.
Idle Air Control (IAC).
Injector harness.
Engine Coolant Temperature (ECT ) sensor.
Manifold Absolute Pressure (MAP) sensor.
Camshaft Position (CMP) sensor.
Vacuum lines.
Vacuum Modulator.
Fuel Pressure Regulator.
Positive Crankcase Ventilation (PCV).
MAP sensor from upper intake manifold.
Upper intake manifold.
Fuel lines at fuel rail and remove from bracket.
Install engine support fixture, J 28467-A.
Right engine mount.
Power steering mounting bolts (support pump aside).
Coolant inlet pipe from coolant outlet housing.
Coolant by-pass at coolant pump and cylinder head.
Radiator hose at coolant outlet housing.
Coolant outlet housing.
Both valve rocker cover.
Lower intake manifold bolts.
IMPORTANT

Retain washers in same orientation on center bolts.
Loosen rocker arms.
Pushrods.
IMPORTANT

Place pushrods in order so they can be installed in their original position.
Intake gasket.
INSPECT

Flatness of inlet flanges.
CLEAN

Gasket material from mating surfaces.
Excess RTV sealant from front and rear ridges of cylinder block.
Sealing surfaces with degreaser.