Chrysler Full-Size Trucks 1989-1996 Repair Guide

Intake Manifold Heater

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REMOVAL & INSTALLATION



This procedure pertains to diesel engines only.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the throttle rod from the throttle lever.
  4.  
  5. Remove the four bolts that attach the air crossover to the intake manifold. Loosen the lower throttle control bracket mounting bolt and move the bracket away from the engine.
  6.  
  7. Loosen the hose clamps on the turbocharger end of the crossover tube and remove the tube and gasket. Cover the turbocharger opening with a clean shop towel.
  8.  
  9. Disconnect the electrical wiring from the intake manifold heater, remove the heater and remove the gasket.
  10.  

To install:
  1. Clean the gasket mounting surface and install a new gasket.
  2.  
  3. Install the intake manifold heater and connect the wiring.
  4.  
  5. Remove the towel from the turbocharger opening and install the air crossover tube and gasket. Tighten the hose clamps.
  6.  
  7. Rotate the throttle control bracket back into place. Torque all mounting bolts to 18 ft. lbs. (24 Nm).
  8.  
  9. Attach the throttle rod to the throttle lever.
  10.  

TESTING



  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the wires from the intake manifold heater.
  4.  
  5. Using an ohmmeter, check the resistance from a good ground to each heater terminal.
  6.  
  7. If there is any resistance, or if the circuit is open, inspect the assembly for dirty or corroded connections.
  8.  
  9. If the resistance is 0 ohms, the heater is functioning properly.
  10.  
  11. If the circuit is open, the heater is defective.
  12.  

 
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