Intake Manifold Replacement

REMOVAL
1. Disconnect the battery negative cable.
2. Drain the cooling system.
3. Remove the engine cover.
4. Remove the air cleaner.
5. Remove the generator.
6. Disconnect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
7. Remove the distributor. Refer to Powertrain Management for the correct procedure.
8. Disconnect and remove the oil pressure sending unit.
9. Disconnect the coolant temperature sending unit(s).
10. Disconnect the injector harness and secure out of the way.
11. Disconnect the IAC, MAP, and TPS connectors from the throttle body.
12. Disconnect the heater hoses and bypass hose.
13. Disconnect the vacuum supply hoses from the intake manifold.
14. Perform the Fuel System Pressure Release procedure (refer to Powertrain Management).
15. Disconnect the fuel supply line.
16. Remove intake manifold bolts.
17. Lift the intake manifold and throttle body out of the engine compartment as an assembly.
18. Remove and discard the flange side gaskets and the front and rear cross-over gaskets.
19. Remove the throttle body bolts and lift the throttle body off the intake manifold. Discard the gasket.

Throttle Body Assembly-MPI:

20. Remove the plenum pan as follows:
a. Turn the intake manifold upside down. Support the manifold.
b Remove the bolts and lift the pan off the manifold. Discard the gasket.

INSTALLATION
1. Install the plenum pan, if removed, as follows:
a. Turn the intake manifold upside down. Support the manifold.
b. Place a new plenum pan gasket onto the seal rail of the intake manifold. Position the pan over the gasket. Align all the gasket and pan holes with the intake manifold.
c. Hand start all bolts.
d. Tighten the bolts, in sequence, as follows:

V6 & V8 ENGINES

Plenum Pan Bolt Tightening Sequence:

^ Step 1-Tighten bolts to 2.7 Nm (24 inch lbs.) torque.
^ Step 2-Tighten bolts to 5.4 Nm (48 inch lbs.) torque.
^ Step 3-Tighten bolts to 9.5 Nm (84 inch lbs.) torque.
^ Step 4-Check that all bolts are tighten to 9.5 Nm (84 inch lbs.) torque.
2. Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 Nm (200 inch lbs.) torque.

Cross-Over Gaskets And Locator Dowels:

3. Place the 4 plastic locator dowels into the holes in the block.
4. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket.
The sealant should be slightly higher than the crossover gaskets, approx. 5 mm (0.2 in).
5. Install the front and rear cross-over gaskets into the dowels.

Intake Manifold Flange Gasket Alignment:

6. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs. The words MANIFOLD SIDE should be visible on the center of each flange gasket.
7. Carefully lower intake manifold into position on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to position the intake manifold. After intake manifold is in place, inspect to make sure seals are in place.
8. Install the intake manifold bolts and tighten as follows:

V-6 ENGINE

Intake Manifold Bolt Torque Sequence - (V-6):

^ Step 1-Tighten bolts 1 and 2 to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time.
^ Step 2-Tighten bolts 3 through 12, in sequence, to 8 Nm (72 inch lbs.) torque.
^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque.
^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque.
^ Step 5-Cheek that all bolts are tighten to 16 Nm (12 ft. lbs.) torque.

V-8 ENGINE

Intake Manifold Bolt Torque Sequence - (V-8):

^ Step 1-Tighten bolts 1 through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time.
^ Step 2-Tighten bolts 5 through 12, in sequence, to 8 Nm (72 inch lbs.) torque.
^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque.
^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque.
^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque.
9. Connect the vacuum supply hoses to the intake manifold.
10. Connect the fuel injector harness to the injectors.
11. Connect the coolant temperature sending unit(s).
12. Connect the heater hoses and bypass hose.
13. Install the distributor assembly. Refer to Powertrain Management for the correct procedure.
14. Install and connect the oil pressure sending unit.
15. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
16. Install the fuel supply line.
17. Connect the MAP, TPS, and IAC connectors.
18. Install the generator and drive belt. Tighten generator mounting bolts to 41 Nm (30 ft. lbs.) torque.
19. Install the air cleaner.
20. Fill cooling system.
21. Connect the battery negative cable.
22. Start engine and check for leaks.
23. Install the engine cover.