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6 A 5 - 6
1977
P O N T I A C SERVICE M A N U A L
Fig.
6A5-1 1
Engine Lifting Tools Installed
-
Typical
R e p l a c e
1. Thoroughly clean gasket surfaces of cylinder head and
exhaust manifold.
2. Place manifold in position against cylinder head and
install two end bolts, leaving about 1/8" clearance between
head and manifold.
3. Slide gasket between manifold and cylinder head.
4. Install remaining bolts.
5. Tighten all bolts evenly and securely to 40 lb. ft.
6. Attach exhaust pipe to manifold and tighten to 30 lb.
ft.
7. Install carburetor air pre-heater shroud
INTAKE MANIFOLD OR GASKET
NOTE: EGR valve removal is necessary before removal
of the intake manifold can be accomplished.
R e m o v e
1. Drain water from radiator.
2. Remove air cleaner and disconnect closed ventilation
pipe at air cleaner, air cleaner vacuum source at manifold and
hot air duct.
3. Remove water outlet fitting bolts and position fitting
out of way, leaving radiator hose attached.
4. Disconnect electrical wires and vacuum hoses from
emission switches and solenoids.
5. Remove spark plug wires from brackets.
6. On cars equipped with power brakes, remove power
brake vacuum hose.
7. Disconnect carburetor vacuum hoses.
8. Disconnect fuel line connecting carburetor and fuel
pump.
9. Disconnect crankcase vent hose.
10.Disconnect throttle cable from carburetor and
manifold.
11. Remove attaching bolts and manifold.
R e p l a c e
When a new manifold is to be installed, transfer
carburetor, adapter, thermostat, choke stove, stove to
carburetor pipes, and thermal vacuum valves.
CAUTION: Care should be taken to avoid
damage to thermal vacuum valve when removing
and installing.
Use new gaskets on those units requiring gaskets and
new O-ring seal between manifold and timing chain cover.
Fig.
6A5-12
Intake Manifold Gasket and Retainers
3 0 1
1. Install new gaskets on cylinder heads, positioning
them with plastic retainers (Fig. 6 ~ 5 - 1 2 ) .
-
2. Install O-ring seal.
3. Install intake manifold on engine.
4. Install cap bolts loosely.
5. Position throttle control bracket assembly on
manifold and install cap bolts.
6. Tighten timing chain cover to intake manifold bolt
until both units are metal-to-metal (15 Ib. ft.).
7. Tighten manifold to head bolts evenly to 40 Ib. ft.
8. Connect throttle cable to carburetor.
9. On cars equipped with power brakes, install vacuum
hose to carburetor.
10.Install fuel pipe connecting carburetor to fuel pump.
11. Install crankcase vent hose.
12. Install water outlet fitting.
13. Connect electrical wires and vacuum hoses.
14. Install spark plug wires on brackets.
15. Install air cleaner, attaching closed ventilation pipe,
vacuum source and hot air duct.
16. Close drain plugs and fill radiator to proper level.
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