Dodge Aspen/Volare 1976-1980 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



Six-Cylinder Engine Combination Manifold


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Fig. Fig. 1 To remove the combination manifold, detach the throttle shaft linkage, and loosen the clamp ...



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Fig. Fig. 2 ... which retains the accelerator cable to the bracket. Remove the cable assembly



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Fig. Fig. 3 Also, remove the transmission linkage clip which retains it to the bracket and detach it



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Fig. Fig. 4 Label and disconnect all vacuum hoses connected to the intake and carburetor



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Fig. Fig. 5 Unbolt the manifold support struts ...



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Fig. Fig. 6 ... then remove them



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Fig. Fig. 7 Remove the heated air shroud securing bolts ...



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Fig. Fig. 8 ... then pull it free of the manifold



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Fig. Fig. 9 Unbolt the exhaust pipe from the manifold



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Fig. Fig. 10 Remove all of the combination manifold attaching nuts and washersmark their positions



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Fig. Fig. 11 Pull the complete manifold and carburetor assembly from the cylinder head



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Fig. Fig. 12 Remove the old gasket and clean the mating surfacesuse a new gasket when installing



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Fig. Fig. 13 Combination manifold nut tightening sequence and washer locations225 cu. in. 6-cylinder

  1. Remove the air cleaner and the fuel line from the carburetor.
  2.  
  3. Disconnect the accelerator linkage. Detach the vacuum lines, crankcase vent hose, carburetor vent line, carburetor air heater, and automatic choke rod.
  4.  
  5. Disconnect the exhaust pipe at the exhaust manifold flange. Remove the carburetor.
  6.  
  7. Remove the manifold assembly-to-cylinder head nuts and washers and remove the intake and exhaust manifolds as a single unit. The manifolds may be separated by removing the three bolts which hold them together.
  8.  
  9. Installation is the reverse of the removal procedure. When installing the manifold assembly, use new gaskets and a good commercial sealer. Loosen the three bolts which secure the intake manifold to the exhaust manifold to maintain proper alignment in relation to each other and the block. Torque these three bolts to 20 ft. lbs. in this sequence: inner bolts first, then the outer two bolts. Tighten the manifold assembly to cylinder head nuts to 10 ft. lbs.
  10.  

V8 Engines


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Fig. Fig. 14 Install new intake manifold gaskets on the 318 and 360 cu. in. 8-cylinder engines. Use RTV sealer around all water ports and in the gasket mating corners



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Fig. Fig. 15 Intake manifold bolt tightening sequence318 and 360 cu. in. 8-cylinder engines

  1. Drain the cooling system and disconnect the battery.
  2.  
  3. Remove the air cleaner and fuel line from the carburetor. Disconnect any interfering air pump system components.
  4.  
  5. Disconnect the accelerator linkage.
  6.  
  7. Remove the vacuum control line between the carburetor and distributor.
  8.  
  9. Remove the distributor cap and wires.
  10.  
  11. Disconnect the coil wires, temperature sending unit wires, and heater and by-pass hoses.
  12.  
  13. Remove the intake manifold securing bolts and remove the manifold and carburetor as an assembly.
  14.  
  15. To install the manifold, reverse the removal procedure. Be sure to tighten the manifold in three steps and remember to use a good commercial sealer on new manifold gaskets.
  16.  

 
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