Question about 1994 Chevrolet G20

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Can't remove intake manifold on 94 Chevy 5.7L TBI

I have removed all the bolts on the edge but the intake still won't braek loose. There are recessed allen head bolts on top of the manifold. Do they need to be removed? Do I need to remove the valve covers?

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  • Philip Boerger Jan 06, 2009

    It turns out that I had missed bolts 1 & 4 on the passenger side cylinder bank. They were buried under years of grease and debris. I had removed bolts in that area that I thought served a dual purpose. Anyway once I removed them the intake came off quite easily. Cleaning off the old gasket and other materials has been another issue....

  • Anonymous Mar 15, 2014

    How to remove broken bolt in intake manifold 96 ford explorer



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Yes, the allen bolts need to come out.

Posted on Jan 05, 2009


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  1. On models equipped with airbag, disable airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING .
  2. On all models, disconnect battery ground cable, drain cooling system and remove air cleaner.
  3. Disconnect accelerator, transmission and cruise control linkages, as equipped.
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  10. Remove alternator upper mounting bracket and EGR solenoids.
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  12. Reverse procedure to install, noting the following:
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Once you're sure, it's probably just that the pressure and heat almost fuses the parts together, so some effort is required. Try using a rubber mallet or a small block of wood and a hammer, so that nothing too hard hits the manifold. Try tapping the manifold from the sides in the direction of sliding it across the face of the engine, not pounding it down onto the engine.

Don't hit it too hard, just lots of light taps to slowly break the seal between the manifold, gasket, and head.

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