Removal and Installation

Fig. 16 Intake manifold bolt tightening sequence:

EXCEPT TURBOCHARGED & EFI ENGINES
1. Disconnect battery ground cable and drain coolant system.
2. Disconnect heater hose from intake manifold and remove air cleaner assembly.
3. Disconnect vacuum hoses as necessary, then the electrical connectors from idle fuel solenoid, bowl vent and choke.
4. Remove EGR supply tube.
5. Raise and support vehicle, then disconnect PVS hose using tool T81P-8564A or equivalent.
6. Remove intake manifold nuts Nos. 2, 3, and 6, Fig. 16, then lower vehicle.
7. Disconnect fuel line at fuel filter and return line at carburetor.
8. Disconnect accelerator cable and, if equipped, speed control cable.
9. On vehicles equipped with automatic transmission, disconnect throttle valve linkage at carburetor, then remove cable bracket attaching bolts.
10. On vehicles equipped with power steering, remove thermactor pump drive belt, thermactor pump, mounting bracket and bypass hose.
11. Remove fuel pump, then three remaining manifold attaching nuts. Remove intake manifold. Do not place manifold on flat surface as damage to gasket surfaces may result.
12. Reverse procedure to install. Tighten intake manifold stud nuts in sequence shown in Fig. 16, to torque listed in Engine Tightening Specifications.

D�Fig. 17 Intake manifold assembly. Turbocharged engine:

TURBOCHARGED & EFI ENGINES
Fuel supply lines will remain pressurized for long periods of time after engine shut-down. This pressure must be relieved before any service is attempted. A valve is provided on the fuel rail assembly for this purpose. To relieve system pressure, remove air cleaner assembly and connect pressure gauge tool No. T80L-9974-A or equivalent, onto fuel diagnostic valve on the fuel rail assembly. Gradually release fuel system pressure.
1. Disconnect battery ground cable.
2. Remove air supply hose from throttle body assembly.
3. Mark then disconnect all electrical connectors and vacuum hoses from intake manifold.
4. Remove EGR supply tube.
5. Disconnect electrical connector from throttle air bypass solenoid.
6. Raise and support vehicle.
7. Remove the bottom 3 intake manifold attaching nuts, Fig. 17.
8. Lower vehicle.
9. Disconnect fuel supply and return lines from intake manifold.
10. Disconnect accelerator cable from throttle body assembly.
11. Disconnect engine wiring harness from shock tower bracket.
12. Disconnect PCV hose from rocker cover and intake manifold.
13. Remove PCV valve.
14. Remove remaining 3 intake manifold attaching nuts, intake manifold and gasket.
15. Reverse procedure to install. Tighten intake manifold stud nuts in sequence shown in Fig. 17, to torque listed in Engine Tightening Specifications.