Intake Manifold Replacement

REMOVAL
1. Disconnect the battery negative cable.
2. Drain the cooling system (refer to Cooling System for the proper procedures).
3. Remove the accessory drive belt.
4. Remove the generator.
5. Remove the air cleaner.
6. Remove the A/C compressor bracket.
7. Disconnect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
8. Disconnect the MAP, IAC, and TPS sensor connectors.
9. Disconnect the fuel injector connectors.
10. Disconnect the coolant temperature sending unit connector(s).
11. Remove the distributor cap and wires.
12. Disconnect the heater hoses and bypass hose.
13. Disconnect the PCV, HVAC, and Speed Control vacuum supply hoses.
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.

Throttle Body Assembly-MPI Typical:

19. Remove the throttle body bolts and lift the throttle body off the intake manifold. Discard the gasket.
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. Hand start all bolts.

Plenum Pan Bolt Tightening Sequence:

d. Tighten the bolts, in sequence, as follows:
^ 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(R) 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 inch).
5. Install the front and rear cross-over gaskets onto 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 A1ANIFOLD 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.

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

8. Install the intake manifold bolts and tighten as follows:
^ 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. Install the fuel supply line. Push until an audible "click" is heard. Verify connection by moderately pulling out on connector.
10. Install distributor cap and wires.
11. Connect the coolant temperature sending unit connector.
12. Connect the fuel injector connectors.
13. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
14. Connect the MAP, TPS, and IAC connectors.
15. Connect the brake booster, HVAC, speed control, and PCV vacuum supply hoses to the intake manifold.
16. Connect the heater hoses and bypass hose.
17. Install the generator and drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 Nm (200 inch lbs.) torque. Refer to Drive Belts, Mounts, Brackets and Accessories for the correct procedures and belt routing schematics.
18. Install the air cleaner.
19. Fill cooling system (refer to Cooling System for the proper procedure).
20. Connect the battery negative cable.