REMOVAL & INSTALLATION
You will need to raise and lower the vehicle several times for this procedure.
- Disconnect the battery.
- Remove the air cleaner assembly. Disconnect all vacuum lines, electrical wiring and fuel lines to the carburetor.
- Remove the throttle linkage.
- Loosen the power steering pump, then remove it.
- Remove the power brake hose from the intake manifold.
- Raise and support the vehicle.
- Remove the exhaust pipe from the manifold.
- Take off the power steering pump.
- Remove the intake and exhaust manifold retaining nuts and bolts.
- Lower the vehicle.
- Remove the carburetor and manifold assembly.
- Remove the carburetor and gasket.
- Separate the manifolds.
- Transfer the studs to the new intake manifold.
- Clean the manifolds and cylinder head.
- Assemble the intake and exhaust manifolds loosely.
- Attach the carburetor to the manifold assembly, then place on the engine.
- Raise and support the vehicle, tighten all the intake and exhaust nuts and bolts to the cylinder head 10-15 inch lbs. (1-2 Nm).
- Tighten the inboard intake to the exhaust manifold nut to 150 inch lbs. (17 Nm). Tighten the outboard intake to exhaust manifold nuts to 200 inch lbs. (23 Nm). Repeat this step until all the intake and exhaust nuts are tightened.
- Tighten the intake and exhaust manifold port flange nuts at the cylinder head, starting at the center and progressing outwards in both directions. Exhaust nuts 150 inch lbs. (17 Nm) and intake 200 inch lbs. (23 Nm). Repeat this step until all the nuts are tightened.
These engines use a combined intake/exhaust manifold gasket. Therefore, the manifolds must always be removed and replaced together.
- Disconnect the negative battery cable. Drain the cooling system.
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
- Remove the air cleaner and hoses.
- If the engine is fuel injected, depressurize the fuel system. Remove all wiring and any hoses connected to the carburetor or injection throttle body and the manifold.
- Disconnect the accelerator linkage.
- Loosen the power steering pump mounting bolts and remove the belt. Disconnect the power brake vacuum hose at the manifold.
- On Canadian cars, only remove the coupling hose connecting the diverter valve and the exhaust manifold air injection tube.
- Disconnect the water hose from the water crossover.
- Raise the vehicle and support it securely. Disconnect the exhaust pipe at the manifold.
- Remove the power steering pump, leaving lines connected, and hang it to one side so the hoses are not stressed.
- Remove the intake manifold support bracket.
- Remove the intake manifold-to-head bolts.
- Lower the vehicle to the floor. Remove the intake manifold.
- Remove the exhaust manifold retaining nuts and remove the exhaust manifold.
- Clean all gasket surfaces and reposition the intake and exhaust manifolds using new gaskets. A composition gasket is installed as-is; a steel gasket must be coated with a sealer such as Chrysler Part No. 3419115 or equivalent.
- Put the exhaust manifold into position, then install the retaining nuts just finger-tight. Put the intake manifold into position, then install all accessible bolts. Raise the car and support it securely.
- Install all the manifold-to-head bolts finger-tight. Install the intake manifold support bracket. Install the power steering pump, bolting it into position with bolts just finger-tight. Connect the exhaust pipe at the manifold, using a new seal, and tighten the bolts and nuts to 21 ft. lbs. (28 Nm).
- Lower the car to the floor. Tighten the manifold nuts and bolts in three stages, starting at the center and progressing outward.
- Connect the power brake vacuum hose to the manifold. Connect the water hose to the water crossover.
- On Canadian cars only: Install the coupling hose connecting the diverter valve and the exhaust manifold air injection tube.
- Install the power steering pump belt and adjust tension.
- Connect the accelerator linkage. Install the air cleaner and hoses.
- Install all wiring and any hoses disconnected from the carburetor or injection throttle body and the manifold. Refill the cooling system, reconnect the battery, start the engine and run it to check for leaks. Refill the cooling system after the engine has reached operating temperature (air has been bled out) and it has cooled off again.