intake CHEVROLET CAMARO 1982 Repair Guide

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 387
TBI EQUIPPED 5.0L ENGINE
1982-1983 CROSSFIRE FUEL INJECTION MODELS

Fig. 7: Crossfire inje ction upper plenum and gasket
1. Disconnect the negative batte ry cable at the battery.
2. Remove the air cleaner assembly.
3. Drain the cooling system.
4. Disconnect the fuel inlet line.
5. Remove the exhaust gas re circulation (EGR) solenoid.
6. Disconnect the wiring fr om the idle air motors, injectors, and the throttle
position sensor (TPS).
7. Disconnect the fuel return line at the rear TBI unit.
8. Remove the power brake booster line.
9. Disconnect the accelerator and crui se control cables, unbolt the cable
bracket from the manifold and tie t he cable and bracket assembly out of
the way.
10. Disconnect the positive crankcase vent ilation valve hose at the manifold
and move the hose aside.
11. Mark and disconnect any vacuum hoses which will interfere with removal of the manifold.
12. If you plan on removing the TBI units from the upper manifold plate, remove the fuel balance tube (connec ting the units) at this time.
13. Remove the bolts which attach the upp er manifold plate (or TBI plate) to
the intake manifold. Lift the TBI and plate assembly off of the intake
manifold.
14. Remove the distributor as previously outlined.
15. Disconnect the upper radiator hos e from the thermostat housing.
16. Disconnect the heater hose fr om the intake manifold.
17. Remove the intake manifold-to- cylinder head bolts and lift the intake
manifold assembly off of the engine.

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 388
To install:
18. Clean the sealing surfaces.
19. Install the gaskets and apply a
3/16 in. (5mm) bead of RTV sealant on the
front and rear ridge of the cylinder case.
20. Hold the gaskets in place by ex tending the RTV bead up onto the gasket
ends. Use sealer at the water passages.
21. Position the intake manifold as sembly onto the engine and install the
intake manifold-to-cylinder head bolts. Torque bolts in sequence to 25-45
ft. lbs. (34-61 Nm).
22. Connect the heater hose to the intake manifold.
23. Connect the upper radiator hose to the thermostat housing.
24. Install the distributor.
25. Position the TBI and plate assembly on the intake manifold with a new
gasket. Install the bolts which attach the upper manifold plate (or TBI
plate) to the intake manifold and torque to specification.
26. If the TBI units on CFI engines were removed, install the fuel balance
tube (connecting the units).
27. Connect vacuum hoses which were disconnected for removal of the manifold.
28. Connect the positive crankcase ventilation valve hose.
29. Install the cable bracket to the m anifold and connect the accelerator and
cruise control cables.
30. Install the power brake booster line.
31. Connect the fuel return line at the TBI unit.
32. Connect the wiring to the idle air motors, injectors, and the throttle
position sensor (TPS).
33. Install the exhaust gas re circulation (EGR) solenoid.
34. Connect the fuel inlet line to the TBI unit.
35. Install the air cleaner assembly.
36. Connect the negative battery cable at the battery.
37. Fill the cooling system.
38. Start the engine and check for leaks.

Fig. 8: Crossfire fuel injection intake manifold bolt torque sequence

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 389
1988-1992 MODELS
1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the air cleaner.
4. Remove the throttle body.
5. Label and unplug all vacuum hose and electrical connections on the manifold.
6. Disconnect the upper radiator hose from the manifold.
7. Mark the distributor position and remove it.
8. Remove the EGR valve, if necessary.
9. Remove the intake manifold bolts and studs.
10. Remove the manifold and discard the gaskets.
To install: 11. Make sure the sealing surfaces are clean.
12. Install the gaskets and apply a
3/16 in. (5mm) bead of RTV sealant on the
front and rear ridge of the cylinder block.
13. Hold the gaskets in place by ex tending the RTV bead up onto the gasket
ends. Use sealer at the water passages.
14. Install the intake manifold.
Sealing of the intake mani fold to the "V" of the engine is obtained by employing
an intermediate torque specification to a ll the attaching bolts, alternately, in the
proper sequence. This step is used to rock the manifold into place before
applying the final torque figur e. Failure to follow this two-step procedure can
result in possible leaks.
15. Install the intake manifold attach ing bolts. Tighten them, using the proper
sequence, to 89 in lbs. (10 Nm).
16. Final torque the bolts, using the proper sequence, to 35 ft lbs. (47 Nm\
).
17. Install the EGR valve.
18. Install the distributor.
19. Connect the upper radiator hose to the thermostat housing.
20. Install the throttle body.
21. Engage all electrical and hose connections.
22. Fill the cooling system.
23. Connect the negative battery cable.
24. Install the air cleaner.
1985-1992 MFI ENGINES
2.8L AND 3.1L ENGINES

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 390

Fig. 9: Intake manifold bolt tor que sequence for 2.8L and 3.1L MFI engines
1. Disconnect the negative battery cable.
2. Drain the coolant.
3. Remove the air inlet duct at t he throttle body and the crankcase vent
pipe.
4. Unplug the vacuum harness from the throttle body.
5. Remove the throttle body.
6. Remove the EGR transfer tube. Discard the gasket.
7. Remove the A/C compressor-to-plenum bracket attaching hardware and
bracket.

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 391
8. Remove the plenum attaching bolts and plenum. Discard the gaskets.
9. Remove the fuel rail.
10. Label and unplug the wires
from the spark plugs.
11. Label and unplug the wires at the coil.
12. Remove the distributor cap and spark plug wires.
13. Mark the distributor position and remove it.
14. Label and disconnect the emission canister hoses.
15. Remove the valve covers.
16. Remove the upper radiator hose at the manifold.
17. Unplug the coolant switch and sensor.
18. Remove the heater inlet pipe from the manifold.
19. Remove the center intake manifold bolts.
20. Remove the center intake mani fold and gasket. Discard the gasket.
21. Remove the transmission dipstick.
22. Remove the manifold bolts.
23. Remove the manifold. Discard t he gaskets and remove the RTV sealant
from the front and rear ridges of the block.
To install: 24. Apply a
3/16 in. (5mm) bead of RTV sealant on the front and rear ridges of
the block. Make sure the surfaces are clean.
25. Install the new gaskets on the cylinder heads. Hold the gaskets in place by extending the RTV bead up onto t he gasket ends. Certain GM intake
gaskets will have to be cut to be install behind the pushrods. Cut these
gaskets as required and only where necessary.
26. Install the intake m anifold along with the intake manifold bolts. Torque
bolts in sequence to 13-25 ft. lbs. ( 18-34 Nm) on 2.8L engines and 19 ft
lbs. (26 Nm) on 3.1L engines.
27. Install the center intake manifold with a new gasket. Tighten the bolts to
15 ft lbs. (21 Nm).
28. Connect the coolant switches.
29. Install the upper radiator hose.
30. Install the valve covers.
31. Install the heater inlet pipe.
32. Connect the emission canister hoses.
33. Install the distributor to the matc hmarks, hold down bolt, spark plug wires
and distributor cap.
34. Install the spark plug wires to th e spark plugs and connect the wires at
the coil.
35. Install the fuel rail.
36. Install the plenum with new gaskets . Tighten the bolts to 18 ft lbs. (25
Nm) on 2.8L engines or 15 ft lbs. (21 Nm) on 3.1L engines.
37. Install the A/C compressor-to-plenum bracket and attaching hardware.
38. Install the EGR transfer tube with a new gasket. Tighten the bolts to 19 ft
lbs. (26 Nm).
39. Install the throttle body.
40. Connect the vacuum harness and ai r inlet duct to the throttle body.
41. Install the transmission dipstick.
42. Connect and other rema ining hoses or wires.

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 392
43. Fill the cooling system.
44. Start the engine and che
ck for proper operation.
5.0L AND 5.7L ENGINES

Fig. 10: Intake manifold bolt torque s equence for V8 engines, except Crossfire
Fuel Injection
1. Disconnect the negative battery cable.
2. Remove the air intake duct.
3. Drain the cooling system.
4. Disconnect the control cabl es from the throttle body.
5. Label and unplug all wiring connectors and hoses from the throttle body
and plenum.
6. Disconnect the AIR hoses from the air management valve.
7. Disconnect the fuel lines.

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 393
8. Label and unplug the spark
plug wires at the cap.
9. Mark the distributor position and remove it.
10. Unplug the injector wiring harness.
11. Remove the left side runner-to-plenum bolts.
12. Remove the left side runner-to-manifold bolts.
13. Remove the right side runner-to-plenum bolts.
14. Remove the right side runner-to-manifold bolts.
15. Remove the EGR solenoid, if necessary.
16. Remove the right side manifold-to-runner bolt.
17. Remove the plenum, right side runners and gaskets. Discard the gaskets.
18. Remove the left side manifold-to-runner bolt.
19. Remove the left side runners and gaskets. Discard the gaskets.
20. Disconnect the upper radiator hos e from the thermostat housing.
21. Remove the EGR valve, if necessary.
22. Unplug any other electrical or hose connections, as necessary.
23. Remove the intake manifold bolts.
24. Remove the intake manifold and gaskets. Discard the gaskets.
To install: 25. Apply a
3/16 in. (5mm) bead of RTV sealant on the front and rear ridges of
the block. Make sure the surfaces are clean.
26. Install the new gaskets on the cylinder heads. Hold the gaskets in place by extending the RTV bead up onto the gasket ends.
27. Install the intake manifold.
Sealing of the intake mani fold to the "V" of the engine is obtained by employing
an intermediate torque specification to a ll the attaching bolts, alternately, in the
proper sequence. This step is used to rock the manifold into place before
applying the final torque figur e. Failure to follow this two-step procedure can
result in possible leaks.
28. Install the intake manifold attach ing bolts. Tighten them, using the proper
sequence, to 89 in lbs. (10 Nm).
29. Final torque the bolts, using the proper sequence, to 35 ft lbs. (47 Nm\
).
30. Install the EGR valve using a new gasket.
31. Connect the upper radiator hose to the thermostat housing.
32. Install new gaskets on the runner s and intake manifold. Make sure the
gasket sealing surfaces are clean.
33. Install the left side runners and finger-tighten the runner-to-manifold
bolts.
34. Install the left side manifold-to-runner bolt. Torque to 25 ft lbs. (34 Nm).
35. Install the right side runners. Fi nger-tighten the runner-to-manifold and
manifold-to-runner bolts.
36. Install the plenum and t he runner-to-plenum bolts.
37. Tighten the runner-to-manifold bolts to 25 ft lbs. (34 Nm). Start in the
center and work outwards.
38. Tighten the right side manifold-to -runner bolt to 25 ft lbs. (34 Nm).

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 406
10. Fill the cooling syst
em, start the engine and check for leaks.
V6 ENGINES 1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the air intake duct and air cleaner, if necessary.
4. Remove the drive belt.
5. Disconnect the heater and radiator hoses from the water pump.
6. Remove the power steering pump bracket and swing aside.
7. Remove the water pump bolts. Mark the bolts to their corresponding
locations for proper installation.
To install: 8. Clean the gasket surface.
9. Install the water pump with a new gasket. Apply sealer to the bolt
threads.
10. Tighten the large bolts to 25 ft lbs. ( 34 Nm), medium bolts to 15 ft lbs. (21
Nm) and the small bolts to 88 inch lbs. (10 Nm).
11. Install the power steering pump bracket.
12. Connect the heater and radiator hoses.
13. Install the drive belt.
14. Install the air cleaner and duct.
15. Fill the cooling syst em. Start the engine and check for leaks.
V8 ENGINES

Fig. 2: Removing the heater hoses

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 408

Fig. 5: Scraping off the old gasket material
1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the air intake duct and air cleaner, if necessary.
4. Remove the drive belt(s) and the water pump pulley.
5. Disconnect the heater and radiator hoses from the water pump.
6. Remove the water pump attaching bolts, then remove the pump. Mark
the bolts to their corresponding loca tions for proper installation.
To install: 7. Clean the gasket mating surfaces.
8. Install the water pump with a new gasket.
9. Install the coolant pump and bolts to the front cover using the dowel pins
as a guide.
10. Tighten the bolts to 30 ft lbs. (41 Nm).
11. Connect the heater and radiator hoses to the water pump.
12. Install the water pump pu lley and the drive belt(s).
13. Fill the cooling syst em. Start the engine and check for leaks.
CYLINDER HEAD
REMOVAL & INSTALLATION
CAUTION - Properly relieve the fuel system pressure before disconnecting any
lines.

GM – CAMARO 1982-1992 – Repair Guide (Checked by WxMax) 409
When servicing the engine, be absolutely sure to mark vacuum hoses and
wiring so that these items
may be properly reconnected during installation. Also,
when disconnecting fittings of metal lines (fuel, power brake vacuum), always
use two flare nut (or line) wrenches. Ho ld the wrench on the large fitting with
pressure on the wrench as if you were tightening the fitting (clockwise), THEN
loosen and disconnect the smaller fitting fr om the larger fitting. If this is not
done, damage to the line will result.
CAUTION - When draining the coolant, keep in mind that cats and dogs are
attracted by the ethylene gl ycol antifreeze, and are quite likely to drink any that
is left in an uncovered container or in puddles on the ground. This will prove
fatal in sufficient quantity. Always drai n the coolant into a sealable container.
Coolant should be reused unless it is contaminated or several years old.
2.5L ENGINE

Fig. 1: Cylinder head bolt torque sequence for 2.5L engine
1. Disconnect the negative battery cable.
2. Drain the engine block and radiator of coolant.
3. Raise and safely support the vehi cle. Remove the exhaust pipe and
lower the vehicle.
4. Remove the oil level indicator tube.
5. Remove the air cleaner.
6. Unplug the electrical and vac uum connections and disconnect the
linkage from the TBI unit.
7. Disconnect the fuel lines.
8. Remove the EGR valve.
9. Disconnect the heater hoses from the intake manifold.
10. Remove the ignition coil.