AMC Coupes/Sedans/Wagons 1975-1988 Repair Information

Intake Manifold

Print

REMOVAL & INSTALLATION 4-121 Engine



See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the intake manifold assembly4-121 engine

  1. Drain the cooling system.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the EGR tube at the exhaust manifold and remove the air cleaner assembly.
  2.  
  3. Disconnect the fuel and vacuum lines and plug the main fuel line to avoid gasoline leakage.
  4.  
  5. Remove the accelerator cable and the air hose from the diverter valve.
  6.  
  7. Remove the fuel pump and the power brake cylinder vacuum hose. Loosen the air conditioner compressor mounting bracket, if so equipped. Do not discharge the system.
  8.  
  9. Remove the water inlet and outlet hoses from the manifold and the PCV hose at the block.
  10.  
  11. Remove the wires from the carburetor, accessories and from the ignition coil.
  12.  
  13. Remove the manifold bracket lower screw, loosen and remove the manifold nuts, and remove the manifold and lift bracket from the engine.
  14.  
  15. Remove the gasket and clean the mating surfaces on the manifold and the cylinder head.
  16.  

To install:
  1. Install the new gasket on the cylinder head.
  2.  
  3. Install the manifold and lift bracket on the engine. Don't tighten the manifold retaining nuts until the EGR tube is connected to the exhaust manifold. Install, but don't tighten, the manifold bracket lower screw.
  4.  
  5. Install the wires on the carburetor, accessories and ignition coil.
  6.  
  7. Install the water inlet and outlet hoses on the manifold and connect the PCV hose at the block.
  8.  
  9. Install the fuel pump and the power brake cylinder vacuum hose. Tighten the air conditioner compressor mounting bracket, if so equipped.
  10.  
  11. Install the accelerator cable and connect the air hose at the diverter valve.
  12.  
  13. Connect the fuel and vacuum lines.
  14.  
  15. Connect the EGR tube at the exhaust manifold and Install the air cleaner assembly. Then tighten the manifold retaining nuts to 18 ft.lb. torque and the bracket lower screw to 30 ft. lbs.
  16.  
  17. Fill the cooling system.
  18.  
  19. Operate the engine for 3 to 5 minutes and check for leaks.
  20.  

4-150 Engine See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Intake manifold component locations4-150 engine

It may be necessary to remove the carburetor from the intake manifold before the manifold is removed.

  1. Disconnect the negative battery cable. Drain the radiator.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air cleaner. Disconnect the fuel pipe and, if necessary, remove the carburetor.
  2.  
  3. Disconnect the coolant hoses from the intake manifold.
  4.  
  5. Disconnect the throttle cable from the bell crank.
  6.  
  7. Disconnect the PCV valve vacuum hose from the intake manifold.
  8.  
  9. If equipped, remove the vacuum advance CTO valve vacuum hoses.
  10.  
  11. Disconnect the system coolant temperature sender wire connector (located on the intake manifold). Disconnect the air temperature sensor wire, if equipped.
  12.  
  13. Disconnect the vacuum hose from the EGR valve.
  14.  
  15. On vehicles equipped with power steering remove the power steering pump and its mounting bracket. Do not detach the power steering pump hoses.
  16.  
  17. Disconnect the intake manifold electric heater wire connector, as required.
  18.  
  19. Disconnect the throttle valve linkage, if equipped with automatic transmission.
  20.  
  21. Disconnect the EGR valve tube from the intake manifold.
  22.  
  23. Remove the intake manifold attaching screws, nuts and clamps. Remove the intake manifold. Discard the gasket.
  24.  
  25. Clean the mating surfaces of the manifold and cylinder head.
  26.  

If the manifold is being replaced, ensure all fittings, etc., are transferred to the replacement manifold.

To install:
  1. Install the intake manifold. Install the intake manifold attaching screws, nuts and clamps. Torque manifold fasteners to 23 ft. lbs.
  2.  
  3. Connect the EGR valve tube to the intake manifold.
  4.  
  5. Connect the throttle valve linkage, if equipped with automatic transmission.
  6.  
  7. Connect the intake manifold electric heater wire connector, as required.
  8.  
  9. On vehicles equipped with power steering install the power steering pump and its mounting bracket.
  10.  
  11. Connect the vacuum to from the EGR valve.
  12.  
  13. Connect the system coolant temperature sender wire connector (located on the intake manifold). Connect the air temperature sensor wire, if equipped.
  14.  
  15. If equipped, install the vacuum advance CTO valve vacuum hoses.
  16.  
  17. If removed, install the carburetor and tighten the mounting bolts to 14 ft. lbs.
  18.  
  19. Connect the PCV valve vacuum hose to the intake manifold.
  20.  
  21. Connect the throttle cable to the bell crank.
  22.  
  23. Connect the fuel pipe.
  24.  
  25. Connect the coolant hoses to the intake manifold.
  26.  
  27. Install the air cleaner.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Fill the cooling system.
  32.  

4-151 Engine See Figure 3

Click image to see an enlarged view

Fig. Fig. 3: Intake manifold bolt tightening sequence4-151 engine

  1. Remove the negative cable.
  2.  
  3. Remove the air cleaner and the PCV valve hose.
  4.  


CAUTION
DO NOT remove the block drain plugs or loosen the radiator draincock with system hot and under pressure because serious burns from the coolant can occur.

  1. Drain the cooling system.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Tag and remove the vacuum hoses (ensure the distributor vacuum advance hose is removed).
  2.  
  3. Disengage the fuel pipe and electrical wire connections from the carburetor.
  4.  
  5. Disconnect the carburetor throttle linkage. Remove the carburetor and the carburetor spacer.
  6.  
  7. Remove the bell crank and throttle linkage brackets and move them to one side for clearance.
  8.  
  9. Remove the heater hose at the intake manifold.
  10.  
  11. Remove the alternator. Note the position of spacers for installation.
  12.  
  13. Remove the manifold-to-cylinder head bolts and remove the manifold.
  14.  

To install:
  1. Position the replacement gasket and install the replacement manifold on the cylinder head. Start all bolts.
  2.  
  3. Tighten all bolts with 37 ft. lbs.
  4.  
  5. Connect the heater hose to the intake manifold.
  6.  
  7. Install the bell crank and throttle linkage brackets.
  8.  
  9. Connect the carburetor throttle linkage to the brackets and bell crank.
  10.  
  11. Install the carburetor spacer and tighten the bolts with 15 ft. lbs.
  12.  
  13. Install the carburetor and gasket. Tighten the nuts with 15 ft. lbs.
  14.  
  15. Install the fuel pipe and engage the electrical wire connections. Install the vacuum hoses.
  16.  
  17. Install the battery negative cable.
  18.  


CAUTION
Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near pulleys, belts or fan. Do not wear loose clothing.

  1. Refill the cooling system. Start the engine and inspect for leaks.
  2.  
  3. Install the air cleaner and the PCV valve hose.
  4.  

6-232 and 258 Engines See Figures 4 through 16

Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the intake and exhaust manifold assembly6-cylinder engines



Click image to see an enlarged view

Fig. Fig. 5: Intake and exhaust manifold components1981-82 6-cylinder engines



Click image to see an enlarged view

Fig. Fig. 6: Intake manifold bolt tightening sequence6-cylinder engines through 1980



Click image to see an enlarged view

Fig. Fig. 7: Intake manifold bolt tightening sequence1981-82 6-cylinder engines



Click image to see an enlarged view

Fig. Fig. 8: Unscrew the air cleaner assembly cover retaining nut ...



Click image to see an enlarged view

Fig. Fig. 9: ... then remove the cover



Click image to see an enlarged view

Fig. Fig. 10: Remove the air filter element ...



Click image to see an enlarged view

Fig. Fig. 11: ... then disconnect the hoses from the housing



Click image to see an enlarged view

Fig. Fig. 12: Remove the air cleaner assembly



Click image to see an enlarged view

Fig. Fig. 13: Remove the intake manifold retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 14: ... then remove the intake manifold assembly



Click image to see an enlarged view

Fig. Fig. 15: Remove the intake manifold gasket



Click image to see an enlarged view

Fig. Fig. 16: Use a gasket scraper to remove any residue from the gasket mating surfaces

The intake manifold and exhaust manifold are mounted externally on the left side of the engine and are attached to the cylinder head. The intake and exhaust manifolds are removed as a unit. On some engines, an exhaust gas recirculation valve is mounted on the side of the intake manifold.

  1. Remove the air cleaner and carburetor.
  2.  
  3. Disconnect the accelerator cable from the accelerator bellcrank.
  4.  
  5. Disconnect the Positive Crankcase System (PCS) vacuum hose from the intake manifold.
  6.  
  7. Disconnect the distributor vacuum hose and electrical wires at the Transmission Controlled Spark (TCS) solenoid vacuum valve.
  8.  
  9. Remove the TCS solenoid vacuum valve and bracket from the intake manifold. In some cases it might not be necessary to remove the TCS unit.
  10.  
  11. If so equipped, disconnect the EGR valve vacuum hoses.
  12.  
  13. Remove the power steering mounting bracket and pump and set it aside without disconnecting the hoses.
  14.  
  15. Remove the EGR valve, if so equipped.
  16.  
  17. Disconnect the exhaust pipe from the manifold flange. Disconnect the spark Coolant Temperature Override (CTO) hoses and remove the oxygen sensor.
  18.  
  19. Remove the manifold attaching bolts, nuts and clamps.
  20.  
  21. Separate the intake manifold and exhaust manifold from the engine as an assembly. Discard the gasket.
  22.  
  23. If either manifold is to be replaced, they should be separated at the heat riser area.
  24.  

To install:
  1. Clean the mating surfaces of the manifolds and the cylinder head before replacing the manifolds. Replace them in reverse order of the above procedure with a new gasket. Tighten the bolts and nuts to the specified torque in the proper sequence.
  2.  
  3. Connect the exhaust pipe to the manifold flange. Torque the nuts to 20 ft. lbs. Connect the spark CTO hoses and install the oxygen sensor.
  4.  
  5. Install the EGR valve, if so equipped.
  6.  
  7. Install the power steering mounting bracket and pump.
  8.  
  9. If so equipped, connect the EGR valve vacuum hoses.
  10.  
  11. Install the TCS solenoid vacuum valve and bracket to the intake manifold.
  12.  
  13. Connect the distributor vacuum hose and electrical wires at the TCS solenoid vacuum valve.
  14.  
  15. Connect the PCS vacuum hose to the intake manifold.
  16.  
  17. Connect the accelerator cable to the accelerator bellcrank.
  18.  
  19. Install the air cleaner and carburetor.
  20.  

8-304, 360 and 401 Engines

  1. Drain the coolant from the radiator.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the spark plug wires. Remove the spark plug wire brackets from the valve covers, and the bypass valve bracket.
  4.  
  5. Disconnect the upper radiator hose and the by-pass hose from the intake manifold. Disconnect the heater hose from the rear of the manifold.
  6.  
  7. Disconnect the ignition coil bracket and lay the coil aside.
  8.  
  9. Disconnect the TCS solenoid vacuum valve from the right side valve cover.
  10.  
  11. Disconnect all lines, hoses, linkages and wires from the carburetor and intake manifold and TCS components as required.
  12.  
  13. Disconnect the air delivery hoses at the air distribution manifolds.
  14.  
  15. Disconnect the air pump diverter valve and lay the valve and the bracket assembly, including the hoses, forward of the engine.
  16.  
  17. Remove the intake manifold after removing the cap bolts that hold it in place. Remove and discard the side gaskets and the end seals.
  18.  

To install:
  1. Clean the mating surfaces of the intake manifold and the cylinder head before replacing the intake manifold. Use new gaskets and tighten the cap bolts to the correct torque. Install in reverse order of the above procedure.
  2.  

There is no specified tighten sequence for this intake manifold. Start at the center bolts and work outward.

  1. Connect the air pump diverter valve.
  2.  
  3. Connect the air delivery hoses at the air distribution manifolds.
  4.  
  5. Connect all lines, hoses, linkages and wires to the carburetor and intake manifold and TCS components as required.
  6.  
  7. Install the TCS solenoid vacuum valve to the right side valve cover.
  8.  
  9. Install the ignition coil bracket.
  10.  
  11. Connect the upper radiator hose and the by-pass hose to the intake manifold. Connect the heater hose to the rear of the manifold.
  12.  
  13. Connect the spark plug wires. Install the spark plug wire brackets on the valve covers, and the bypass valve bracket.
  14.  
  15. Install the air cleaner assembly.
  16.  
  17. Fill the cooling system.
  18.  

 
label.common.footer.alt.autozoneLogo