An intake manifold operates to distribute the air and fuel mixture provided by the engine's carburetor to each of the engine's cylinders and also to provide a pathway for the engine's antifreeze to flow through to cool the engine. Because fluids are constantly passing though the intake manifold, the manifold uses four gaskets to prevent leaks. Over time, intake manifold gaskets corrode, resulting in leaks. Although fluid can leak onto the exterior of the engine, leaky intake manifold gaskets typically result in the mixing of fluid within the engine. Thankfully, replacing the intake manifold gaskets on a Chevy Malibu is a relatively straightforward operation.
Remove the air cleaner assembly from the top of the carburetor by first twisting the single wing nut located at the top of the air cleaner in a counterclockwise direction, then by lifting the air cleaner assembly off of the carburetor.
Disconnect the fuel line and the throttle linkage from the carburetor, followed by any vacuum lines attached to the carburetor. The fuel line is held into place with a single hose clamp. To remove the fuel line, first loosen the screw on the hose clamp with a flathead screwdriver, then pull the fuel line away from the carburetor. Any vacuum lines attached to the carburetor, such as for a vacuum advance distributor, can be simply pulled off of the carburetor. Remove the throttle linkage from the carburetor by removing the single screw that attaches the linkage to the carburetor, then by pulling the linkage away.
Remove the carburetor from the intake manifold by removing each of the four nuts that hold the carburetor in place with a wrench, then by lifting the carburetor away from the engine. There is one nut located at each corner of the base of the carburetor.
Remove the distributor and the upper radiator hose from the intake manifold. The distributor is located at the rear of the intake manifold and is held in place with a single bolt that must be removed with a wrench. The upper radiator hose attaches to the front of the intake manifold and can be removed by loosening the screw on the hose's clamp with a screwdriver, then pulling the hose away from the intake manifold.
Remove each of the intake manifold's bolts with a wrench, then lift the intake manifold off of the engine. Clean the four surfaces which surround the bottom of the intake manifold, as well as the surfaces on the engine, with a gasket scraper to ensure that these surfaces are free from debris.
Coat one side of each of the four intake manifold gaskets with gasket sealer. Place both of the two longer gaskets against the mating surface on the intake manifold. The side of each gasket coated with gasket sealer must face the intake manifold. Place one shorter gasket against the manifold's mating surface on the front of the engine, and the other shorter gasket against the manifold's mating surface on the back of the engine. Coat the exposed sides of all four gaskets with gasket sealer, then lower the intake manifold onto the engine. Insert each of the manifold's bolts through the manifold and into the engine, then tighten each bolt with a wrench.
Insert the distributor into the back of the intake manifold and secure the distributor into place with the distributor's single bolt. Slide the upper radiator hose onto the front of the intake manifold, then tighten the hose clamp to secure the hose in place.
Lower the carburetor onto the intake manifold, then install and tighten each of the four carburetor mounting nuts. Connect the fuel line and any vacuum lines to the carburetor, followed by the throttle linkage.
Install the air cleaner assembly onto the top of the carburetor, then tighten the wing nut located on top of the assembly to complete the replacement process.
