Removal and Installation

Fig. 16 Intake manifold bolt tightening sequence:

EXCEPT EFI ENGINES
1. Raise and secure hood in open position, then disconnect battery ground cable.
2. Partially drain cooling system, then disconnect heater hose from intake manifold.
3. Remove air cleaner assembly, then disconnect vacuum hoses.
4. Disconnect electrical connectors from choke cap wire, bowl vent and idle fuel solenoid, then remove EGR supply tube.
5. Raise and support vehicle, then remove PVS hose connectors using tool No. T81P-8564-A or equivalent. label connectors, then position aside.
6. Remove bottom three intake manifold attaching nuts, then lower vehicle.
7. Disconnect fuel line at fuel filter, then the return line at carburetor.
8. Disconnect accelerator, then the speed control cable, if equipped.
9. On models with automatic transaxle, Disconnect throttle valve linkage at carburetor, then remove cable bracket attaching bolts.
10. On models with power steering, remove thermactor pump drive belt, pump, pump mounting bracket, then the thermactor bypass hose.
11. Remove fuel pump, then the remaining intake valve attaching bolts.
12. Reverse procedures to install. Tighten retaining nuts in sequence shown, Fig. 7, to torque value listed in Engine Tightening Specifications.

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.
To remove upper intake manifold assembly, proceed as follows:
1. Disconnect engine air cleaner outlet tube from throttle body.
2. Unplug throttle position sensor from wiring harness.
3. Disconnect vacuum lines from upper manifold assembly.
4. Disconnect EGR tube at manifold connection.
5. Unplug air bypass valve connector.
6. Remove manifold upper support bracket top bolt.
7. Remove five upper manifold attaching bolts.
8. Remove upper manifold assembly and gasket.
9. Reverse procedure to install.