Question about 1984 Toyota Corolla

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Intake manifold gasket needs replaced

My friends cannot afford the 600.00 estimate to have their intake manifold gasket replaced on their 84 toyota corolla SR5
They have asked my husband and son for help.
How complicated is it to do this on this car?
What is the process?
Is it something that a do-it-yourselfer could handle?

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It is a pretty basic job the important things to remember is to remove everything sequentially. in other words make a note of which bolts go where. remove the intake and clean both mating surfaces, usually you dont need gasket sealant for an intake manifold. reassemble in the order removed thats about it.

Posted on Jan 20, 2009


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1. Disconnect the negative battery cable from the remote jumper terminal located at the right strut tower.
2. Remove the air inlet resonator and tube.
3. Remove the throttle actuator cables from the throttle arm and bracket.
4. Disconnect Secondary Runner Valve (SRV), Manifold Tuning Valve (MTV), Throttle Position Sensor (TPS), Idle Air Control (IAC) motor electrical connectors.
5. Remove the electrical connector and the Intake Air Temperature/Manifold Absolute Pressure (TMAP) sensor.
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7. Remove right and left intake manifold supports.
8. Remove support brackets at the intake manifold front corners and MTV.
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    Need to replace the intake manifold

    3.8L Engine (most common) Upper Intake Manifold To Remove:
    1. Drain the cooling system.
    2. Remove or disconnect the following:
      • Negative battery cable.
      • Fuel injector sight shield.
      • Air cleaner intake duct.
      • Right spark plug wires from the ignition control module and reposition.
    3. Relieve the fuel pressure.
    4. Remove or disconnect the following:
      • Fuel rail assembly.
      • Brake booster hose from the vacuum source manifold in the upper intake manifold.
      • Exhaust Gas Recirculation Valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield.
      • Throttle body support bracket upper bolt.
    5. Disconnect the electrical connectors from the following:
      • EVAP purge solenoid
      • Throttle Position (T/P) sensor
      • Idle Air Control (IAC) valve
      • Manifold Absolute Pressure (MAP) sensor
      • Mass Air Flow (MAF) sensor
      • EVAP purge solenoid vacuum line from the throttle body.
      • Accelerator and the cruise control cables with the bracket from the throttle body.
    6. Remove or disconnect the following:
      • Upper intake manifold bolts and stud.
      • Clean the upper intake manifold bolt threads.
    7. Remove or disconnect the following:
      • Upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
      • Upper-to-lower intake manifold carrier gasket from the upper intake manifold.
    8. If the upper intake manifold is being replaced, remove the following:
      • Throttle body assembly.
      • Manifold Absolute Pressure (MAP) sensor.
      • Positive Crankcase Ventilation (PCV) valve.
      • Vacuum source manifold.
    Upper intake manifold bolt torque sequence (3.8L engine) gm-03-38-530.gif

    To Install:
    1. If the manifold was replaced, install or connect the following:
      • Vacuum source manifold.
      • Positive Crankcase Ventilation (PCV) valve.
      • Manifold Absolute Pressure (MAP) sensor.
      • Throttle body assembly.
      • Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
    2. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold. NOTE: Apply thread lock compound, to the bolt threads before assembly.
    3. Install or connect the following:
      • Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
      • Accelerator and the cruise control cables with the bracket to the throttle body.
      • EVAP purge solenoid vacuum line to the throttle body.
    4. Connect the electrical connectors to the following:
      • Mass Air Flow (MAF) sensor
      • Manifold Absolute Pressure (MAP) sensor
      • Idle Air Control (IAC) valve
      • Throttle Position (T/P) sensor
      • EVAP purge solenoid
    5. Install or connect the following:
      • Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
      • EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
      • Brake booster hose to the vacuum source manifold.
      • Fuel rail assembly.
      • Right spark plug wires.
      • Air cleaner intake duct.
      • Fuel injector sight shield.
    6. Connect the negative battery cable.
    7. Fill the cooling system.
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    1. Remove or disconnect the following:
      • Upper intake manifold.
      • Generator brace.
      • Drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe.
      • Exhaust gas recirculation EGR outlet pipe bolt from the lower intake manifold.
      • Radiator inlet hose from the water outlet housing.
      • ECT sensor electrical connector.
      • Right upper engine mount strut bracket.
      • Generator brace bracket bolts.
      • Generator brace bracket.
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      • Lower intake manifold.
      • Lower intake manifold seals.
      • Lower intake manifold gaskets.
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      • Water outlet housing bolt and stud
      • Water outlet housing
      • Gasket and the thermostat.
      • ECT sensor.
    3. Inspect the flatness of inlet flanges.
    4. Clean the intake manifold mating surfaces.
    5. Clean the intake manifold bolts and bolt holes of adhesive compound.
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    1. If removed, install the ECT sensor.
      • Tighten the ECT sensor to 18 ft. lbs. (25 Nm)
    2. If removed, install the thermostat, the gasket, and the water outlet housing.
    3. If removed, install the water outlet housing bolt and the stud.
      • Tighten the bolt and stud to 20 ft. lbs. (27 Nm)
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      • Lower intake manifold seals.
      • Lower intake manifold.
      • Lower intake manifold bolts.
      NOTE: Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.
    5. Tighten the lower intake manifold bolts in sequence to 11 ft. lbs. (15 Nm) gmpc_v6_5.gif

    6. Install or connect the following:
      • Generator brace bracket.
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      • Right upper engine mount strut bracket.
      • ECT sensor electrical connector.
      • Radiator inlet hose to the water outlet housing.
      • EGR outlet pipe to the lower intake manifold.
      • EGR outlet pipe bolt to the lower intake manifold. Tighten the bolt to 21 ft. lbs. (29 Nm)
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      • Generator brace.
      • Upper intake manifold.
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    2. Drain the cooling system.
    3. Remove the supercharger.
    4. Remove the thermostat housing.
    5. Remove the EGR pipe at the intake manifold.
    6. Disconnect the electrical connection at the temperature sensor.
    7. Remove the intake manifold and gaskets.
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    2. Install the intake manifold gaskets.
    3. Align the coolant bypass tube with the opening in the intake manifold and install the manifold. Tighten the bolts to 11 lb ft (15 Nm).
    4. Install the electrical connector to the temperature sensor.
    5. Install the EGR pipe to the intake manifold.
    6. Install the thermostat housing.
    7. Install the supercharger.
    8. Fill the cooling system.
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