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5 - Disconnect all throttle linkages.
6 - Identify or number the ignition wires. Numbering the ignition wires will help in reconnecting them during MPI system
assembly. Remove ignition wires from the coil and spark plugs.
7 - Remove ignition cables and distributor cap as one unit.
8 - Note the position of the rotor and the distributor housing. Mark rotor position on the distributor and mark distributor
housing position on the engine block to ensure accurate re-assembly. After marking the position of the rotor and the
distributor, remove the distributor.
9 - Loosen all manifold bolts before removal. Remove the manifold bolts.
DANGER!
FROM THIS POINT FORWARD, USE EXTRA CAUTION TO ENSURE NO GASKET MATERIAL, OR OTHER
FOREIGN MATTER ENTERS OIL PASSAGES, HEAD PORTS, OR ANY OTHER LOCATION WHERE AN
OBSTRUCTION MIGHT CAUSE DAMAGE.
10 - Remove the existing manifold. If required, remove valve covers.
11 - Remove the mechanical fuel pump and pusher rod and install a mechanical fuel pump block-off plate.
9.1 Preparing the Manifold for Installation
1 - Protect the lifter galley with clean shop rags. Close off the ports by stuffing them with clean shop rags.
WARNING!
Failure to cover the intake opening with a clean towel could result in dirt or debris entering the engine.
Dirt or debris in the induction system can cause engine damage which may require a complete
engine overhaul.
2 - Using a gasket scraper, remove gasket material from heads and block. When all loose material is removed, carefully
remove the shop rags from the ports, ensuring that no material falls into passages. Using a shop vac, remove all debris
from the lifter gallery.
3 - Inspect carefully. Use a flashlight to inspect the interior of all air, oil, and water passages.
4 - Soak a clean shop rag with solvent, and clean all sealing surfaces. Surfaces must be completely clean to ensure a
reliable seal between the components and gaskets.
9.2 Installation of MPI Pro-Jection Manifold
WARNING!
Use new gaskets. Be sure you are using the proper gasket for your engine, for aluminum manifolds, as
recommended by the manufacturer.
1 - Install the manifold gasket, carefully following the instructions provided by the gasket manufacturer.
2 - Use O
sensor compatible RTV (again following manufacturer's instructions) around all ports and water passages.
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3 - Carefully position the manifold on the heads, so the bolt holes in the manifold are centered over bolt hoses in the heads.
4 - Hand start bolts, but do not tighten.
NOTE:
Because the MPI Projection system is shipped fully assembled, you may need to temporarily remove the fuel rails or
other components, to access the center manifold bolts. Refer to Fig 1.
5 - Remove the four bolts which hold the air valve body (1).
6 - Remove the throttle cable bracket.
7 - Lift the map sensor (12) out of the way and let it rest on top of the air valve (1).
8 - Remove air valve (1).
9 - Remove the four bolts holding down the fuel rails (4) and (7) and retrieve the fuel rails with the fuel injectors.
10 - Torque down the manifold bolts as recommended in the engine manual.
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Troubleshooting
