
5
9.0 REMOVAL OF EXISTING FUEL SYSTEM
1. Disconnect the ground side of the battery.
2. Drain the cooling system. Remove the cooling system hoses and thermostat housing.
3. Drain the fuel tank, then disconnect the fuel supply line or disconnect the fuel supply line and plug the hose.
4. Disconnect all throttle linkages.
5. Identify or number the ignition wires. Numbering the ignition wires will help in reconnecting them during MPI system
assembly. Remove the ignition wires from the coil and spark plugs.
6. Remove the ignition cables and distributor cap as one unit.
7. 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. It is easiest if the rotor points directly towards the firewall.
8. 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.
9. Remove the existing manifold. If required, remove valve covers.
10. Remove the mechanical fuel pump and push 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 AVENGER EFI 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. The manifold comes with the rails, fittings, and crossovers loosely installed in the proper locations. The crossover lines will
have to be removed in order to install the intake manifold bolts. The injectors, fittings, rails, and crossovers should be
assembled and tightened after the manifold is installed on the engine.
2. Install the manifold gaskets, carefully following the instructions provided by the gasket manufacturer.
3. Use O
2
sensor compatible RTV (again following manufacturer's instructions) around all water passages and for end seals
if end seal gaskets are not used.
4. Carefully position the manifold on the heads, so the bolt holes in the manifold are centered over bolt hoses in the heads.
5. Hand start all the bolts.
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