Chrysler Full-Size Trucks 1967-1988 Repair Guide

Intake Manifold

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The V6 and V8 engines use an intake manifold installed between the cylinder heads. This is in contrast with the inline 6 cylinder gasoline engines which are equipped with combination manifolds. As the name implies, these manifolds combine the intake and exhaust manifolds by securing them together with screws.

REMOVAL & INSTALLATION

It is always advisable to purchase new parts before proceeding with a job. A valve cover gasket, RTV sealant if needed, and intake gasket set can be purchased separately if need be. If you are planning on doing more than this procedure, a head set, which comes with all gaskets will do just as good. It is best to look at the engine to see if while you are doing a job, you may need to replace a hose or wire that is damaged. Even though it may not pertain to the current procedure, it may only take but a minute to fix another problem which is about to occur.

V6 and V8 Gasoline Engines

See Figures 1 through 8

  1. Drain the cooling system and disconnect the negative battery cable.
  2.  
  3. Remove the alternator, carburetor air cleaner and fuel line. Identify and tag all connections.
  4.  
  5. Disconnect the accelerator linkage.
  6.  
  7. Remove vacuum control between carburetor and distributor.
  8.  
  9. Remove the distributor cap and wires. Mark the individual wires.
  10.  
  11. Disconnect and tag the coil wires, temperature sending unit wire, heater hoses and bypass hose.
  12.  
  13. If necessary, disconnect the exhaust downpipe at the exhaust manifolds. Remove the nuts and washers attaching the exhaust manifold assembly to the cylinder head, then remove the manifolds.
  14.  
  15. Remove the bolts attaching the intake manifold to the cylinder heads.
  16.  



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Fig. Fig. 1: Once all interfering components are removed, loosen and remove the retainers from the intake manifold

  1. Remove the ignition coil and and any remaining hoses or wires around the intake manifold. Finally, remove the intake manifold, with the carburetor intact, from the engine.
  2.  
  3. If replacing the carburetor, remove the hardware securing it to the intake manifold.
  4.  



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Fig. Fig. 2: Remove the intake manifold as an assembly with carburetor installed

  1. Remove all traces of intake manifold gasket material from the intake manifold as well as the cylinder heads. Inspect the manifold for cracks or any other damage in case you may need to replace it.
  2.  



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Fig. Fig. 3: Discard of the old intake gasket



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Fig. Fig. 4: Remove any other gasket materials, clean and scrape area completely

  1. Installation is the reverse of the above procedure. Make sure you use new gaskets before installing the manifold assembly. Tighten the intake manifold to head bolts in the sequence illustrated, from center alternating out.
  2.  



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Fig. Fig. 5: On a V engine, place new gaskets on the top and side portions of the cylinder head. Use sealer in accordance with gasket manufacturer recommendations



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Fig. Fig. 6: Correct placement of the side intake manifold gasket. Notice the coolant metering hole, and lettering corresponding to the cylinder head side



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Fig. Fig. 7: Manifold torque sequence on V6's



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Fig. Fig. 8: V8 manifold torque sequence

  1. Tighten the exhaust manifold mounting nuts to the required torque which is listed in the specifications chart of this section.
  2.  

Refer to theCombination Manifoldinformation found in this section for information on inline 6 cylinder manifold removal and installation

Diesel Engines
  1. Drain the cooling system.
  2.  
  3. Disconnect the battery ground cable.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Disconnect the fuel lines at the fuel filter, transfer pump and injection pump. See Fuel System .
  8.  
  9. Drain the fuel filter and remove it from the back of the manifold. See General Information & Maintenance .
  10.  
  11. Remove the manifold and air cleaner mounting bracket bolts.
  12.  
  13. Disconnect the injection lines at the injection pump and remove the nozzle holder from the cylinder head. See Fuel System .
  14.  
  15. Remove the fuel line clamps from the manifold and push the fuel lines up and out of the way.
  16.  
  17. Remove the manifold and gaskets from the head.
  18.  

To install:
  1. Install the manifold and new gaskets on the head.
  2.  
  3. Install the fuel lines and clamps on the manifold.
  4.  
  5. Connect the injection lines at the injection pump.
  6.  
  7. Install the nozzle holder on the cylinder head. See Fuel System .
  8.  
  9. Install the manifold and air cleaner mounting bracket bolts.
  10.  
  11. Install the fuel filter on the back of the manifold. See General Information & Maintenance .
  12.  
  13. Connect the fuel lines at the fuel filter, transfer pump and injection pump. See Fuel System .
  14.  
  15. Install the air cleaner.
  16.  
  17. Connect the battery ground cable.
  18.  
  19. Fill the cooling system.
  20.  

 
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