Intake Manifold: Service and Repair

REMOVAL
1. Disconnect the negative cable from the battery,
2. Drain the cooling system.
3. Remove the accessory drive belt.

Generator And A/C Compressor Braces:

4. Remove the generator brace and generator.
5. Remove the A/C compressor brace. Remove the compressor and set aside.

Air Intake Housing:

6. Remove the air cleaner cover and filter. Remove the air cleaner housing. Discard the gasket.
7. Perform the Fuel Pressure Release procedure. Disconnect the fuel lines.
8. Disconnect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
9. Remove the coil assemblies with the ignition cables.
10. Disconnect the vacuum lines.
11. Disconnect the heater hoses and bypass hose.
12. Remove the closed crankcase ventilation and evaporation control systems.

Upper Intake Manifold And Throttle Body:

13. Remove the throttle body bolts and lift the throttle body off the upper intake manifold. Discard the gasket.
14. Remove upper intake manifold bolts.
15. Lift the upper intake manifold out of the engine compartment. Discard the gasket.

Lower Intake Manifold:

16. Remove the lower intake manifold bolts and remove the manifold.

Lower Intake Manifold Gaskets:

17. Discard the lower intake manifold gaskets.

INSTALLATION

Intake Manifold Flange Gasket Alignment:

1. Install the intake manifold side gaskets. Be sure that the locator dowels are positioned in the head.
2. Peel off the protective paper (blue - rear and brown - front) and press firmly onto the block. BE SURE THE BLOCK IS OIL FREE. Aligning slots in end seals with notches in intake manifold gaskets.
3. Insert Mopar(R) Silicone Rubber Adhesive Sealant, or equivalent, into the four comer pockets. Fill the pocket, but DO NOT overfill.
4. The lower intake manifold MUST be installed within 3 minutes of sealant application. Carefully lower intake manifold into position on the cylinder block and heads. After intake manifold is in place, inspect to make sure seals and gaskets are in place. Finger start all the lower intake bolts.
5. Tighten the lower intake manifold bolts in sequence to 54 Nm (40 ft. lbs.) torque.
6. Using a new gasket, position the upper intake manifold onto the lower intake manifold.
7. Finger start all bolts, alternate one side to the other.
8. Tighten upper intake manifold bolts in sequence to 22 Nm (16 ft. lbs.) torque.
9. Using a new gasket, install the throttle body onto the upper intake manifold. Tighten the bolts to 23 Nm (200 inch lbs.) torque.
10. Install closed crankcase ventilation and evaporation control systems.
11. Connect the heater hoses and bypass hose.
12. Connect the vacuum lines.
13. Install the coil assemblies and the ignition cables.
14. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
15. Install the fuel lines.
16. Using a new gasket, install the air cleaner housing. Tighten the nuts to 11 Nm (96 inch lbs.) torque. Install the air cleaner filter and cover.
17. Install the A/C compressor. Position the compressor brace and install the bolts. Tighten the brace bolts to 41 Nm (30 ft. lbs.) torque.
18. Install the generator. Position the generator brace and install the bolts. Tighten the brace bolts to 41 Nm (30 ft. lbs.) torque.
19. Install the accessory drive belt.
20. Fill cooling system.
21. Connect the negative cable to the battery.