Chrysler Full-Size Trucks 1989-1996 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



2.5L Engine

Please refer to the combination manifold procedure for the 2.5L engine.

3.9L Engine

See Figures 1, 2, 3, 4, 5, 6 and 7

  1. Relieve the fuel pressure. Disconnect the negative battery cable from the battery and drain the cooling system.
  2.  

CAUTIONWhen draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container.

  1. Remove the air pump and bracket. Removal of the bracket will allow for easier installation of the left front corner of the intake manifold.
  2.  



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Fig. Fig. 1: Torque sequence for the V6 engine intake manifold

  1. Remove the air cleaner assembly. Unbolt the air conditioning compressor and lay it to the side, if equipped. Remove the distributor cap with all wires attached.
  2.  



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Fig. Fig. 2: Seal the intake manifold as shown-V6 engines

  1. Disconnect all wires, hoses, linkages and cables from the throttle body. Disconnect the fuel line.
  2.  
  3. Disconnect the ignition coil, coolant temperature sending unit wire and all other connectors along the wiring harness connected to items on the intake manifold.
  4.  



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Fig. Fig. 3: Install the intake manifold side gaskets as shown-V6 engine, left side

  1. Disconnect the heater hose, upper radiator hose and the lower bypass hose clamp.
  2.  



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Fig. Fig. 4: Remove the throttle cable from the throttle body

  1. Remove the cylinder head covers.
  2.  



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Fig. Fig. 5: Unbolt the intake manifold from the engine



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Fig. Fig. 6: When unbolted, remove the intake manifold (complete with throttle body) from the engine

  1. Unbolt the intake manifold from the heads and remove the intake manifold assembly. Disassemble the manifold as required and clean out the exhaust crossover passages.
  2.  



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Fig. Fig. 7: An engine with its intake manifold removed-clean the mating surfaces before reinstalling

To install:
  1. Clean and dry the intake manifold contact surfaces. Coat the intake manifold side gaskets very lightly with sealer and install the gaskets to the heads. Cutouts at the front of the gaskets differentiate the right and left sides.
  2.  
  3. Apply a thin uniform coat of quick dry cement to the front and rear intake manifold gaskets and mounting surfaces on the block and apply a thin bead of sealer to each of the four corners. Install the front and rear gaskets engaging the hole in the block and the tangs from the head gaskets. Apply a second thin bead of sealer above the gaskets in the four corners.
  4.  
  5. Carefully lower the intake manifold into position engaging the bypass hose; after it is satisfactorily in place, inspect the gaskets to make sure they have not become dislodged.
  6.  
  7. Install the intake manifold bolts with the aspirator tube, air pump bracket and kickdown linkage bracket in place, if equipped. Tighten the bolts in sequence to 25 ft. lbs. (34 Nm). Repeat the sequence retightening the bolts to a final torque of 40 ft. lbs. (54 Nm) and repeat the second step to ensure all bolts are accurately torqued.
  8.  
  9. Clean and dry the cylinder head cover mating surfaces, bolts and bolt holes. Install the cylinder head covers with a new gasket. Tighten the screws or nuts to 95 inch lbs. (11 Nm).
  10.  
  11. Connect the heater hose, upper radiator hose and the lower bypass hose clamp.
  12.  
  13. Connect the ignition coil, coolant temperature sending unit wire and all other connectors that were disconnected along the wiring harness.
  14.  
  15. Install the air conditioning compressor, if equipped. Install the distributor cap and all spark plug wires.
  16.  
  17. Install air pump.
  18.  
  19. Connect all wires, hoses, cables and the fuel line to the throttle body. Install the air cleaner assembly.
  20.  
  21. Fill the cooling system.
  22.  
  23. Connect the negative battery cable. Turn the ignition ON to repressurize the fuel system by activating the fuel pump. Check for leaks.
  24.  

5.2L and 5.9L Engines

See Figures 8, 9 and 10

  1. Drain the cooling system and disconnect the negative battery cable.
  2.  

CAUTIONWhen draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container.

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Fig. Fig. 8: Seal the intake manifold as shown-V8 engines

  1. Remove alternator and air cleaner.
  2.  



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Fig. Fig. 9: Be careful to properly position the intake manifold gaskets-V8 engine's left bank shown

  1. Disconnect accelerator linkage.
  2.  



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Fig. Fig. 10: V8 engine intake manifold tightening sequence

  1. Depressurize the fuel system and disconnect the fuel line.
  2.  
  3. Remove the distributor cap and wires.
  4.  
  5. Disconnect coil wires, temperature sending unit wire, heater hoses and bypass hose.
  6.  
  7. Remove intake manifold and throttle body as an assembly.
  8.  

To install:
  1. Clean the gasket surfaces so they are clean and dry.
  2.  
  3. Position the intake manifold and install. If the fasteners were severely rusted when removed, use new fasteners.
  4.  
  5. Tighten the intake manifold to head bolts in the sequence illustrated.
  6.  

8.0L Engines

See Figures 11, 12, 13 and 14

  1. Drain the cooling system and disconnect the negative battery cable.
  2.  
  3. Remove alternator and air cleaner.
  4.  
  5. Remove the serpentine belt.
  6.  



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Fig. Fig. 11: Details of the upper intake manifold and throttle body assembly-V10 engine

  1. Remove the alternator and its brace.
  2.  
  3. Remove the air conditioning compressor brace, remove the compressor and set it aside without disconnecting the lines.
  4.  



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Fig. Fig. 12: Details of the lower intake manifold-V10 engine

  1. Remove the air cleaner cover and filter. Remove the filter. Discard the gasket.
  2.  
  3. Depressurize the fuel system and disconnect the fuel line.
  4.  
  5. Disconnect accelerator linkage, and if so equipped, the speed control and transmission kickdown cables.
  6.  



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Fig. Fig. 13: Exploded view of the lower intake manifold gaskets-V10 engine

  1. Remove the coil assemblies. Disconnect the vacuum lines.
  2.  
  3. Disconnect the heater hoses and bypass hose.
  4.  



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Fig. Fig. 14: Align the intake manifold flange gasket-V10 engine

  1. Remove the closed crankcase ventilation and evaporation control systems.
  2.  
  3. Remove throttle body and lift it off the upper intake manifold. Discard the gasket.
  4.  
  5. Remove the front upper intake manifold bolts. Retain the three rear bolts in the up position with tape or rubber bands.
  6.  
  7. Lift the upper intake manifold out of the engine bay. Discard the gasket.
  8.  
  9. Remove the lower intake manifold bolts and remove the manifold. Discard the gasket.
  10.  

To install:
  1. Clean the manifolds and mounting surfaces with solvent and let dry or dry completely with compressed air.
  2.  
  3. Inspect the surfaces for cracks and for warpage using a straightedge.
  4.  
  5. With the locator dowels in place on the head, install the intake manifold side gaskets.
  6.  
  7. When sure that the block is oil-FREE, peel off the paper (blue-rear, brown-front) and press firmly onto the block. Align the slots in the end seals with the notches in the intake manifold gaskets.
  8.  
  9. Into each of the four corner pockets, insert Mopar® Silicon Rubber Adhesive Sealant, or equivalent. Do NOT overfill.
  10.  
  11. The lower intake manifold must be installed within three minutes of the sealant's having been applied. After in place, inspect to be sure all the gaskets and the seals are in their proper places. Finger-start all lower intake bolts.
  12.  
  13. Tighten in sequence to 40 ft. lbs. (54 Nm).
  14.  
  15. Install a new gasket and the upper intake manifold and finger-tighten all bolts. Alternate from one side to the other.
  16.  
  17. Tighten the bolts to 16 ft. lbs. (22 Nm).
  18.  
  19. Install a new gasket and the throttle body onto the upper intake manifold. Tighten the bolts to 17 ft. lbs. (23 Nm).
  20.  
  21. Install the closed crankcase ventilation and evaporation control systems.
  22.  
  23. Connect the heater hoses and bypass hose.
  24.  
  25. Connect the vacuum lines.
  26.  
  27. Install the oil assemblies and the ignition cables.
  28.  
  29. Connect the accelerator linkage, and if so equipped, the speed control and transmission kickdown cables.
  30.  
  31. Install the fuel lines.
  32.  
  33. Using a new gasket, install the air cleaner housing. Tighten the nuts to 96 inch lbs. (11 Nm). Install the air cleaner assembly and its cover.
  34.  
  35. Install the air conditioning compressor. Install the brace, tightening the bolts to 30 ft. lbs. (41 Nm).
  36.  
  37. Install the serpentine belt.
  38.  
  39. Fill the cooling system and connect the negative battery cable.
  40.  

Diesel Engine

See Figures 15, 16, 17 and 18



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Fig. Fig. 15: Remove the components that block the removal of the intake manifold-diesel engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the throttle control bracket and linkage.
  4.  
  5. Remove the high pressure fuel lines.
  6.  



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Fig. Fig. 16: Remove the air crossover tube for access to the intake manifold-diesel engine

  1. Disconnect the intake manifold heater.
  2.  



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Fig. Fig. 17: Exploded view of the intake air heater that must be removed to access the intake manifold

  1. Disconnect the fuel heater ground wire from the intake manifold.
  2.  



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Fig. Fig. 18: Remove the intake manifold cover on the diesel engine-note the location of the fuel heater ground wire

  1. Remove the air crossover tube and the intake manifold heater.
  2.  
  3. Remove the manifold cover and gasket. Clean the gasket sealing surface.
  4.  

To install:
  1. Install the new gasket and cover. Some of the bolt holes are drilled through. Apply liquid Teflon® sealant to these bolts. Torque all bolts to 18 ft. lbs. (24 Nm).
  2.  
  3. Assemble all intake piping and intake manifold heater with the throttle control bracket and linkage.
  4.  
  5. Connect the fuel heater ground wiring.
  6.  
  7. Install and bleed the high pressure fuel lines.
  8.  
  9. Connect the negative battery cable.
  10.  

 
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