Intake Manifold

REMOVAL & INSTALLATION

WARNING
Do not perform this operation on a warm engine. Wait until the engine is cold.

1. Remove the spare tire from the engine compartment.
2. Tag and disconnect the emission control system hoses.
3. Remove the mounting bracket screws and the air cleaner assembly. On 1800 Turbo models, remove the air intake duct.
4. Drain the cooling system and detach all of the water hoses from the thermostat housing.

   Fig. 3: Tag and disconnect the emission control system hoses

   Fig. 4: Disconnect the throttle cable

   CAUTION
   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.

5. Disconnect the thermoswitch connector.

   Fig. 5: Use a flare nut wrench to disconnect the fuel line on carbureted engines

6. On models having a distributor vacuum control valve, disconnect the hoses and leads from it. Disconnect the anti-dieseling solenoid leads, as well.
7. On ff–1 and 1300G models, which have an air injection system, perform the following:
   1. Disconnect the lines from the anti–afterburn valve.
   2. Unbolt the air injection manifold mounting brackets from the intake manifold.
   3. Remove the bypass valve (if so equipped).
8. On 1974 and later models, disconnect the following:
   1. Automatic choke-to-voltage regulator wire at the connector.
   2. EGR solenoid wiring (if so equipped).
   3. The EGR pipe by removing the nuts which secure it to the intake manifold and the cylinder head (if so equipped).

      Fig. 6: Unbolt the intake manifold and remove it from the heads

9. Disconnect the throttle cable and manual choke cable (if so equipped) from their brackets.
10. Disconnect the fuel line from the carburetor. On 1800 Turbo models, disengage the hose clamps, pull off hoses, and remove the fuel pressure regulator assembly. Also, unbolt and remove the vacuum pipe assembly.
11. Unbolt the intake manifold from the cylinder heads and remove the manifold assembly. On 1982–84 models, air cleaner brackets will come off as the unit is unbolted. Make sure to note locations of these brackets and remove them. Be careful not to lose any of the gaskets.

    NOTE: Cover the intake ports in the cylinder head while the manifold is removed to prevent anything from being dropped in them.

12. The manifold may be disassembled further by removing the carburetor or throttle body and the applicable emission control system components from it. See Section 4.
13. On ff–1 models, the intake manifold halves may be separated from the thermostat housing.
14. Be sure to use new gaskets when installing the intake manifold. Tighten the bolts evenly, in stages, to the specifications given in the Torque Specifications chart. Adjust the choke and throttle linkages, as detailed in Section 5.