Intake Manifold: Service and Repair

Fig. 5 Crankcase ventilation system. V8 engine:

Fig. 6 Air crossover installation. Typical:

V8 ENGINE

1. Disconnect ground cables from batteries.
2. Remove air cleaner assembly.
3. Drain cooling system, then disconnect upper radiator hose and thermostat bypass hose from water pump outlet. Disconnect heater hose and vacuum hose from water control valve.
4. Remove breather pipes from valve covers and air crossover, Fig. 5.
5. Remove air crossover and cap intake manifold, Fig. 6.
6. Disconnect throttle rod and return spring. If equipped with Cruise Control, remove servo.
7. Remove hairpin clip from bellcrank and disconnect the cables. Remove throttle and throttle valve cables from intake manifold brackets and position cables aside.
8. Disconnect wiring as necessary.
9. Disconnect or remove alternator and A/C compressor brackets as necessary.
10. Disconnect fuel line from fuel pump and filter and remove fuel filter and bracket.
11. Disconnect lines from injector nozzles and remove injection pump, refer to ``Injection Nozzle Replace, Injection Pump & Lines.'' Cap all open fuel line lines and fittings.
12. Disconnect fuel return line from injection pump.

Fig. 7 Vacuum pump & oil pump drive assembly:

Fig. 8 Intake manifold drain tube installation:

Fig. 9 Intake manifold tightening sequence. V8 engine:

13. Disconnect vacuum lines at vacuum pump. Remove vacuum pump, if equipped with A/C, or oil pump drive assembly, if less A/C, Fig. 7.
14. Remove intake manifold drain tube, Fig. 8.
15. Remove intake manifold bolts and the intake manifold.
16. Remove adapter seal and injection pump adapter.
17. Reverse procedure to install. Torque intake manifold bolts in sequence, Fig. 9, to specifications.