Intake Manifold: Service and Repair
REMOVAL1. Disconnect the negative cable from the battery.
2. Drain the cooling system.
3. Remove the A/C compressor.
4. Remove the generator.
5. Remove the accessory drive bracket.
6. Remove the air cleaner.
7. Perform the Fuel System 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 return spring.
10. Remove the distributor cap and wires.
11. Disconnect the coil wires.
12. Disconnect the heat indicator sending unit wire.
13. Disconnect the heater hoses and bypass hose.
14. Remove the closed crankcase ventilation and evaporation control systems.
15. Remove intake manifold bolts.
16. Lift the intake manifold and throttle body out of the engine compartment as an assembly.
17. Remove and discard the flange side gaskets and the front and rear end seals.
18. Remove the throttle body bolts and lift the throttle body off the intake manifold (Fig. 70). Discard the gasket.
19. If required, remove the plenum pan and gasket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with compressed air. Clean cylinder block front and rear gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all foreign material).
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge.
INSTALLATION
1. If removed, position new plenum gasket and install plenum pan (Fig. 71).
2. Tighten plenum pan mounting bolts as follows:
^ Step 1. Tighten bolts to 5.4 Nm (48 in. lbs.)
^ Step 2. Tighten bolts to 9.5 Nm (84 in. lbs.)
^ Step 3. Check all bolts are at 9.5 Nm (84 in. lbs.)
3. 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 (Fig. 73). The words MANIFOLD SIDE should be visible on the center of each flange gasket.
4. Apply Mopar GEN II 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 approximately 5 mm (0.2 in.) in diameter and 15 mm (0.6 in.) long.
5. Install the front and rear end seals (Fig. 72) Make sure the molded dowel pins on the end seals fully enter the corresponding holes in the cylinder block.
6. Carefully lower intake manifold into position on the cylinder block and cylinder heads. After intake manifold is in place, inspect to make sure seals are in place.
7. Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 Nm (200 in. lbs.) torque.
8. Install the intake manifold bolts and tighten as follows (Fig. 74):
^ Step 1. Tighten bolts 1 through 4 to 8 Nm (72 in. lbs.) Tighten in alternating steps 1.4 Nm (12 in. lbs.) at a time
^ Step 2. Tighten bolts 5 through 12 to 8 Nm (72 in. lbs.)
^ Step 3. Check all bolts are torqued to 8 Nm (72 in. lbs.)
^ Step 4. Tighten all bolts in sequence to 16 Nm (12 ft. lbs.)
^ Step 5. Check all bolts are torqued to 16 Nm (12 ft. lbs.)
9. Install closed crankcase ventilation and evaporation control systems.
10. Connect the coil wires.
11. Connect the heat indicator sending unit wire.
12. Connect the heater hoses and bypass hose.
13. Install distributor cap and wires.
14. Hook up the return spring.
15. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
16. Install the fuel lines.
17. Install the accessory drive bracket and A/C compressor.
18. Install the generator and drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque.
19. Install the air cleaner.
20. Fill cooling system.
21. Connect the negative cable to the battery.