Before Installation:

• Inspect the intake for shipping damage
• Read and re-read all instructions that come with your new intake
• Run a tap through all threaded holes to make sure they are in good shape
• Inspect (and replace or rebuild if necessary) your carburetor and ignition system
• Check all rubber lines (fuel and vacuum) for cracks or dry rot and replace as necessary
• Thoroughly clean the engine to prevent dirt from falling into the lifter valley or intake ports
• Flush the radiator to prevent contaminants in the new intake.

Required Tools:

• Various box and open end wrenches
• SAE and/or Metric socket set
• Pliers (various types)
• Screwdrivers (regular and phillips)
• Distributor wrench
• Gasket scraper or putty knife
• Hammer
• Tape measure
• Torque wrench
• Shop towels (Old towels are great unless your wife finds out)
• Bucket
• Timing light
• Vacuum guage

Additional Supplies:

• Intake gaskets (if not included with the intake)
• Valve cover gaskets
• Pipe plugs if needed
• Gasket sealant (gaskacinch or equivalent)
• RTV silicon sealant
• Masking tape
• Silly putty or modeling clay
• Chalk
• Paper and pencil
• Anti-freeze
• Teflon tape
• Thermostat and gasket
• Radiator and heater hoses
• Belts
• Digital camera (optional)

Removing the stock manifold:

1. Make sure the engine is completely cooled before beginning.
2. Disconnect battery
3. Drain coolant
4. Remove the air cleaner assembly
5. Use camera if available to get detailed photos of all linkages and vacuum lines. Take detailed notes of all locations and label everything with masking tape.
6. Remove the gas cap to reduce the pressure in the fuel line
7. Remove the fuel line from the carb and plug to prevent a fuel spill
8. Replace the gas cap
9. Remove all linkage from the carburetor.
10. Label and remove all sensor wires and coil wire (if not labeled in step 5)
11. Label and remove all vacuum gauges (if not labeled in step 5)
12. Remove all accessories and brackets that are attached to the intake or will get in the way of removal
13. Remove hoses, water outlet housing, and thermostat (this is also an ideal time to replace the belts)
14. Remove the carburetor
15. Remove the distributor (noting/labeling the position of the distributor in the intake and the position of the rotor in the distributor)
16. Remove valve covers
17. Remove the stock intake

Preparing for installation of the new intake:

1. Lay rags in the lifter valley and stuff paper towels into the intake ports
2. Use the gasket scraper to carefully remove the old gaskets and any sealant residue
3. Remove the paper from the intake ports
4. Carefully remove the rags from the lifter valley, making sure that no dirt falls into the ports or lifter valley
5. Wipe all surfaces with clean rags soaked in lacquer thinner to remove and oil or grease
6. Remove and thoroughly clean all fittings, pipe plugs and carb studs from the stock intake
7. Reinstall onto new intake, making sure to use teflon tape on all pipe thread fittings and plugs.

Installation:

1. Coat the mounting surface of the head and both sides of the gasket with gasket sealant
2. Apply a bead of RTV sealant around the water passages and across the manifold end seal surface.
3. After a few minutes the gasket sealant will become tacky to the touch
4. Carefully place the gaskets on the head surface, making sure the bolt holes and ports are aligned
5. Apply gasket sealant to the port surface of the intake and RTV sealant around all water passages. Let it sit until it becomes tacky
6. Place the manifold on the engine, being very careful to make sure all ports and bolt holes are lined up
7. Apply RTV sealant to all bolt threads that are exposed to oil or coolant
8. Start all intake bolts by hand, then tighten to specification using torque wrench in the sequence specified in the instructions.
9. Reinstall all accessories, wiring and hoses in the opposite order they were removed referring to the pictures and notes taken at the beginning.

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