REMOVAL & INSTALLATION
See Figures 1 through 6
When servicing late model vehicles, be absolutely sure to mark vacuum hoses and wiring so that these items may be properly reconnected during installation. Also, when disconnecting fittings of metal lines (fuel, power brake vacuum), always use two flare nut (or line) wrenches. Hold the wrench on the large fitting with pressure on the wrench as if you were tightening the fitting (clockwise), THEN loosen and disconnect the smaller fitting from the larger fitting. If this is not done, damage to the line will result.
- Remove the air cleaner assembly.
- Disconnect the battery cables at the battery.
- Raise and support the front of the vehicle.
- Remove the coolant drain plugs from the lower portion of the engine block and allow the coolant to drain.
- Reinstall and tighten the drain plugs and lower the vehicle.
When servicing 1963-81 models, continue with the following step and follow through to step 16. When servicing 1982 models, skip to step 17 and follow through to step 32.
- On single-carburetor models, disconnect the fuel line at the carburetor. On models equipped with three-two barrel carburetors, disconnect the fuel feed line from the three-way junction block at the front carburetor.
- On 1963-67 models, remove the accelerator rod which connects the carburetor linkage to the accelerator linkage at the firewall. On 1968-81 models, disconnect the accelerator cable at the carburetor.
- On 1968-72 models, unbolt the accelerator cable from the bracket and tie the cable out of the way. On 1973-81 models, unbolt the accelerator cable bracket from the carburetor and tie the cable and bracket assembly out of the way.
- Disconnect the transmission linkage (or cable) and/or cruise control cable at the carburetor.
- Disconnect the vacuum hoses from the distributor and power brake unit, if so equipped. If the power brake line uses a flex hose connected to an engine-mounted metal line, disconnect the flex hose at the metal line.
- Disconnect the ignition coil and temperature sending switch wiring (if the switch is mounted on the intake manifold instead of the cylinder head).
- Mark and disconnect any remaining vacuum lines which will interfere with the removal of the intake manifold and carburetor assembly.
- Remove the distributor as previously outlined.
- If the upper alternator or air conditioning compressor mounting brackets are mounted to the intake manifold, remove the brackets.
- Disconnect the heater hose(s) at the manifold and the upper radiator hose at the thermostat housing.
- Remove the intake manifold and carburetor as an assembly.
The following steps apply only to 1982 models.
- Disconnect the fuel inlet line at the front Throttle Body Injection (TBI) unit.
- Remove the Exhaust Gas Recirculation (EGR) solenoid.
- Disconnect the wiring from the idle air motors, injectors, and the Throttle Position Sensor (TPS).
- Disconnect the fuel return line at the rear TBI unit.
- Remove the power brake booster line.
- Disconnect the accelerator and cruise control cables, unbolt the cable bracket from the manifold and tie the cable and bracket assembly out of the way.
- Disconnect the air injection hose at the check valve and the air control valve.
- Unbolt the air injection pump and move it out of the way.
- Disconnect the Positive Crankcase Ventilation valve hose at the manifold and move the hose aside.
- Mark and disconnect any vacuum hoses which will interfere with removal of the manifold.
- If you plan on removing the TBI units from the upper manifold plate, remove the fuel balance tube (connecting the units) at this time.
- Remove the bolts which attach the upper manifold plate (or TBI plate) to the intake manifold. Lift the TBI and plate assembly off of the intake manifold.
- Remove the distributor as previously outlined.
- Disconnect the upper radiator hose from the thermostat housing.
- Disconnect the heater hose from the intake manifold.
- Remove the intake manifold-to-cylinder head bolts and lift the intake manifold assembly off of the engine.
Installation is the reverse of removal procedures. Note the following points when installing the manifold:
- Components originally sealed with RTV sealer must be resealed with RTV. Conversely; if no RTV was used originally, it is not necessary to use during assembly.
- It IS NOT necessary to remove all old RTV before applying the new RTV; just remove the loose pieces and seal over the remaining RTV. If the RTV must be applied around bolt holes, run the bead of RTV on the inside of the holes.
- If available, use sealing tape on the threads of male fuel line fittings during assembly.
- Replenish the cooling system with the proper amount and quality of coolant.
- Before starting the engine, make sure that the throttle return springs are connected properly and the linkage does not bind in any way.
- If disturbed during manifold removal, adjust the drive belt(s) to recommended tension.
- After the engine is started, check for leaks and readjust the ignition timing, if necessary.