Before You Begin:
* Disconnect the battery: This is crucial to prevent electrical shorts.
* Gather your tools: You'll need sockets, wrenches (both metric and standard), a ratchet, extensions, a torque wrench, screwdrivers (Phillips and flathead), possibly a breaker bar, and potentially a manifold gasket removal tool.
* Repair Manual: Obtain a factory service manual or a reputable aftermarket repair manual specific to your 1996 Chevy Tahoe. This is essential for precise instructions, torque specifications, and component locations.
* Cleanliness: Work in a clean area to prevent debris from falling into the engine. Have shop rags handy.
* Safety First: Wear safety glasses and gloves.
Step-by-Step (General Outline):
1. Disconnect Components:
* Fuel Lines: Disconnect the fuel lines from the fuel rail. Be extremely cautious! Fuel is under pressure. Relieve pressure by cranking the engine until it stops (with the fuel pump relay disconnected). Properly plug the fuel lines to prevent leaks.
* Vacuum Lines: Disconnect all vacuum lines connected to the intake manifold. Take pictures or label them carefully to ensure correct reassembly.
* Throttle Cable: Disconnect the throttle cable from the throttle body.
* Throttle Position Sensor (TPS): Unplug the electrical connector.
* Intake Air Temperature (IAT) Sensor: Unplug the electrical connector.
* Mass Air Flow (MAF) Sensor: Unplug the electrical connector and carefully remove the MAF sensor from its housing (if it's located on the air intake tube before the throttle body).
* Coolant Lines: If applicable, disconnect any coolant lines connected to the intake manifold. Be prepared for coolant spillage.
* PCV Valve: Disconnect the PCV valve hoses.
* Fuel Injectors: Disconnect the electrical connectors from the fuel injectors. Some may have clips holding them in place.
* Exhaust Manifold Bolts (May Be Necessary): Depending on the specific interference, you may need to partially loosen or even remove the exhaust manifold bolts to give you enough clearance to remove the intake manifold.
2. Remove the Upper Intake Manifold:
* Unbolt: Carefully remove all the bolts securing the upper intake manifold to the lower intake manifold. These are typically located on top of the manifold.
* Lift Off: Gently lift off the upper intake manifold. Be mindful of any gaskets that might stick to either the upper or lower manifold.
3. Remove the Lower Intake Manifold:
* Unbolt: Remove all bolts securing the lower intake manifold to the cylinder heads. These bolts are usually located on the sides and bottom of the manifold. This is often the most challenging part. You might need extensions, universal joints, and possibly a breaker bar to loosen stubborn bolts.
* Lift Off: Carefully lift off the lower intake manifold. Again, watch for gaskets.
4. Clean and Inspect:
* Clean the mating surfaces of the intake manifold and cylinder heads thoroughly. Use a suitable cleaner and rags. Remove any old gasket material.
* Inspect the intake manifold and head gaskets for damage. Replace them if necessary.
5. Reassembly:
* Follow the removal steps in reverse order, ensuring all bolts are tightened to the proper torque specifications as indicated in your repair manual. Use new gaskets.
Important Notes:
* Torque Specifications: Absolutely critical! Incorrect torque can lead to leaks and damage.
* Gaskets: Always replace all gaskets. Reusing old gaskets can cause leaks.
* Difficulty: This is not a simple job. If you're not comfortable working on engines, it's best to seek professional help.
* Engine Coolant: Be prepared for coolant spillage, especially if you disconnect the coolant lines.
* Pictures: Take lots of pictures during disassembly to aid in reassembly.
This is a simplified overview. Consult your repair manual for detailed instructions, torque specifications, and diagrams specific to your 1996 Chevy Tahoe's engine. Failure to follow proper procedures can result in engine damage.
