Intake Manifold: Service and Repair

Remove or Disconnect
1. Negative battery cable.
2. Air cleaner.
3. Throttle controls at the bell crank.
4. Carburetor (if necessary).
5. Fuel and vacuum lines from the manifold, EGR valve (if equipped) and EFE valve (if equipped).
6. AIR pump and bracket.
7. PCV hose.
8. Exhaust pipe.
9. Manifold heat stove.
10. Clamps (32), bolts (31), nuts (33) and washers.
11. Manifold assembly and gasket.
Disassemble
1. Bolt (35) and nuts (40).
2. Manifolds (34 and 39).
3. Gasket (38).
Clean
^ All manifold bolts and studs. After cleaning, apply engine oil to the threads.
^ All traces of old gaskets from the cylinder head and manifolds.

Inspect
^ Manifolds for cracks or damage to gasket surfaces.
^ Operation of EFE or manifold heat valve (if equipped).
^ Gaskets, if necessary to diagnose a leakage problem.

Measure
^ Manifold distortion. Lay a straight edge along the full length of the manifold exhaust port faces and measure any gaps between the straight edge and the port faces. If at any point a gap of 0.80 mm (0.030-inch) or more exists, it is likely that the manifold has distorted to a point where it will not seal properly. If a good exhaust seal is to be expected, the exhaust manifold must be replaced.

Assemble
1. Gasket (38) to the exhaust manifold (34).
2. Intake manifold (39) to the exhaust manifold.
3. Both (35), washers (36) and nuts (40). LEAVE FINGER TIGHT.

Install or Connect
1. New gasket over the manifold studs on the cylinder head.
2. Manifold assembly.
3. Clamps (32).
4. Bolts (31) and nuts (33).
Important
^ Always tighten the manifold to cylinder head bolts and nuts (31 and 33) BEFORE tightening the manifold center bolt and nuts (35 and 40).

Tighten
^ Bolts (31) and nuts (33) to 52 N.m (38 ft. lbs.).
^ Bolts (35) and nuts (40) to 80 N.m (44 ft. lbs.).

5. Manifold heat stove.
6. Exhaust pipe.
7. PCV hose.
8. AIR pump and bracket.
9. Fuel and vacuum lines from the manifold, EGR valve (if equipped) and EFE valve (If equipped).
10. Carburetor (if removed).
11. Throttle controls at the bell crank.
12. Air cleaner.
13. Negative battery cable.
Adjust
^ Engine idle speed, if necessary.