Intake Manifold: Service and Repair
INTAKE MANIFOLD
REMOVAL
1. Disconnect negative cable from battery.
2. Remove the wiper module.
3. Remove resonator assembly and air inlet hose.
4. Disconnect electrical connectors for the following components:
- Manifold Absolute Pressure (MAP) Sensor
- Intake Air Temperature (IAT) Sensor
- Throttle Position (TPS) Sensor
- Coolant Temperature (CTS) Sensor
5. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose.
6. Remove generator and set aside.
NOTE: It is not necessary to remove lines or remove Freon from A/C compressor.
7. Remove air conditioning compressor and set aside.
8. Bleed fuel system.
9. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts.
10. Remove intake manifold and IAFM as an assembly.
CLEANING
NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.
Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.
INSPECTION
1. Inspect the intake sealing surface for cracks, nicks and distortion.
2. Inspect the intake manifold vacuum hose fittings for looseness or blockage.
INSTALLATION
1. Install intake manifold seals. Install the intake manifold seals (3) and Positive Crankcase Ventilation (PCV) seal (1). Connect the short runner valve electrical connector as you move the intake manifold in place. Position the intake manifold (1) in place.
2. Position intake manifold and IAFM.
3. Apply Mopar Lock & Seal Adhesive lower case Adhesive to the intake manifold bolts.Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside. Torque fasteners to 12 Nm (105 inch lbs.).
4. Connect electrical connectors for the following components:
- Manifold Absolute Pressure (MAP) Sensor
- Intake Air Temperature (IAT) Sensor
- Throttle Position (TPS) Sensor
- Coolant Temperature (CTS) Sensor
- Idle Air Control (IAC) Motor
5. Install generator.
6. Install A/C compressor.
7. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose.
8. Install the wiper module.
9. Install resonator assembly and air inlet hose.
10. Connect negative cable to battery.