Intake Manifold

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





Fig. 33

4. Remove the generator brace and generator (Fig. 33).
5. Remove the A/C compressor brace (Fig. 33). Remove the compressor and set aside.





Fig. 34

6. Remove the air cleaner cover and filter. Remove the air cleaner housing (Fig. 34). Discard the gasket.
7. Perform the Fuel System Pressure release procedure. Refer to Powertrain Management. 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 wires.
10. Disconnect the vacuum lines.
11. Disconnect the heater hoses and bypass hose.
12. Remove the closed crankcase ventilation and evaporation control systems.





Fig. 35

13. Remove the throttle body bolts and lift the throttle body off the upper intake manifold (Fig. 35). Discard the gasket.
14. Remove upper intake manifold bolts.
15. Lift the upper intake manifold out of the engine compartment (Fig. 35). Discard the gasket.





Fig. 36

16. Remove the lower intake manifold bolts and remove the manifold (Fig. 36).





Fig. 37

17. Discard the lower intake manifold gaskets (Fig. 37).

INSTALLATION





Fig. 38

1. Install the intake manifold side gaskets. Be sure that the locator dowels are positioned in the head (Fig. 38).
2. Position the cross-over gaskets and press firmly onto the block (Fig. 37). BE SURE THE BLOCK IS OIL FREE.
3. Insert Mopar GEN II Silicone Rubber Adhesive Sealant, or equivalent, into 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 approximately 5 mm (0.2 in.) in diameter. (Fig. 37).
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 (Fig. 36).
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 (Fig. 35).
9. Using a new gasket, install the throttle body onto the upper intake manifold. Tighten the bolts to 23 Nm (200 in. 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 wires.
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 in. 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 (refer to Engine, Drive Belts, Mounts, Brackets and Accessories).
20. Fill cooling system (refer to Cooling System for the proper procedure).
21. Connect the negative cable to the battery.
22. Start engine check for leaks.