REMOVAL & INSTALLATION
140 cid (2.3L) Engine
- Drain the cooling system.
- Remove the air cleaner and disconnect the throttle linkage from the carburetor.
- Disconnect the fuel and vacuum lines from the carburetor.
- Detach the carburetor solenoid wire at the quick-disconnect.
- Remove the choke water housing and thermostatic spring from the carburetor.
- Disconnect the water outlet and crankcase ventilation hoses from the intake manifold.
- Disconnect the deceleration valve-to-carburetor hose at the carburetor.
- By starting at each end and working toward the middle, remove the intake manifold attaching bolts and remove the manifold.
- Clean all old gasket material from the manifold and cylinder head.
- Apply water-resistant sealer to the intake manifold gasket and position it on the cylinder head.
- Install the intake manifold attaching nuts. Follow the sequence shown in the illustration.
- Connect the water and crankcase ventilation hoses to the intake manifold.
- Connect the deceleration valve-to-carburetor hose to the carburetor.
- Position the choke water housing and thermostatic spring on the carburetor and engage the end of the spring coil in the slot and the choke adjusting lever. Align the tab on the spring housing. Tighten the choke water housing attaching screws.
- Connect the carburetor solenoid wire.
- Connect the fuel and vacuum lines to the carburetor.
- Connect the throttle linkage to the carburetor.
- Install the air cleaner and fill the cooling system.
On this engine, the intake manifold is integral with the cylinder head and cannot be removed.255 cid (4.2L) and 302 cid (5.0L) Engines
- Drain the cooling system and disconnect the negative battery cable.
- Disconnect the upper radiator hose and water pump bypass hose from the thermostat housing. Disconnect the water temperature sending unit wire. Remove the heater hose from the automatic choke housing bracket and disconnect the hose from the intake manifold.
- Remove the air cleaner. Disconnect the automatic choke heat chamber air inlet hose at the inlet tube near the right valve cover. Remove the crankcase ventilation hose and intake duct assembly. On all models so equipped, disconnect the thermactor air hose from the check valve at the rear of the intake manifold and loosen the hose clamp at the bracket. Remove the air hose and thermactor air bypass valve from the bracket and position it to one side.
- Remove all carburetor linkage and automatic transmission kick-down linkage that attaches to the manifold. Disconnect the fuel line, choke heat tube, and any vacuum lines from the carburetor or intake manifold, marking them for installation.
- Disconnect the distributor vacuum hoses from the distributor. Remove the distributor cap and mark the relative position of the rotor on the distributor housing. Disconnect the spark plug wires at the spark plugs and the primary and secondary wires from the coil. Remove the distributor hold-down bolt and remove the distributor.
- If equipped with air conditioning, remove the brackets retaining the compressor to the intake manifold.
- Remove the manifold attaching bolts. Lift off the intake manifold and carburetor as an assembly.
If it is necessary to pry the manifold to loosen it from the engine, be careful not to damage any gasket sealing surfaces. Always discard all old gaskets and attaching bolt sealing washers.
- Clean all gasket surfaces and firmly cement new gaskets in place, using non-hardening sealer. Make sure that the gaskets interlock with the seal tabs, and that the gasket holes align with those in the cylinder heads.
- Installation is the reverse of the removal procedure. Be sure to run a finger around the seal area on the installed manifold to make sure that the seals did not slip out during installation. Finally, tighten the intake manifold bolts in the proper sequence, and recheck the torque after the engine is warm.