Chrysler Full-Size Trucks 1997-2000 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



2.5L Engine
  1. Disconnect the battery negative cable.
  2.  
  3. Remove the air cleaner hose and resonator from the throttle body and air cleaner.
  4.  
  5. Remove the accessory drive belt from the power steering pump.
  6.  
  7. Remove the power steering pump and brackets from the water pump and secure it out of the way.
  8.  
  9. Depressurize the fuel system and disconnect the fuel line from the fuel rail. Note that some lines may require a special tool for removal/installation.
  10.  
  11. Disconnect the throttle, cruise control and transmission line pressure cable (if fitted) from the throttle body and cable bracket.
  12.  


WARNING
Do NOT pry the cruise control cable off with pliers or screwdrivers. Use fingers only.

  1. Disconnect the electrical wiring. Secure all wiring out of the way.
  2.  
  3. Disconnect the vacuum, brake booster, CCV and MAP hoses.
  4.  
  5. Remove the vacuum harness.
  6.  
  7. Referring to the illustration of the 2.5L manifold, remove bolts 2 through 5 securing the manifold to the cylinder head. Loosen bolt 1 and nuts 6 and 7 .
  8.  
  9. Remove the intake manifold and gaskets.
  10.  

To install:

  1. Use new O-rings at the quick-connect fuel line coupling.
  2.  
  3. Fit a new intake manifold gasket.
  4.  
  5. Replace the intake manifold and finger tighten the fasteners.
  6.  
  7. Referring to the illustration, tighten bolt 1 to 30 ft. lbs. (41 Nm). Then, install the intake manifold and tighten bolts 2 through 5 to 23 ft. lbs. (31 Nm).
  8.  
  9. Install the exhaust manifold spacers over the mounting studs, and then tighten nuts 6 and 7 to 23 ft. lbs. (31 Nm).
  10.  
  11. The remainder of the procedure is the reverse of removal. Tighten power steering pump bolts and tensioner bracket to 21 ft. lbs. (28 Nm).
  12.  



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Fig. Intake/exhaust manifold mounting hardware-2.5L engine

3.9L, 5.2L, 5.9L Gasoline Engines
  1. Disconnect the battery negative cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the alternator.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Depressurize the fuel system and disconnect the supply line from the fuel rail.
  10.  
  11. Disconnect the throttle, cruise control and transmission kick down cables (if fitted) from the throttle body bracket.
  12.  



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Fig. Removing the intake manifold bolts



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Fig. Intake manifold air temperature sensor

  1. Remove the distributor cap and wires.
  2.  
  3. Disconnect the fuel system and throttle body wiring connectors.
  4.  
  5. Disconnect the coil wires and sensors: MAP, IAT, CTS, and IAC (if equipped).
  6.  
  7. Disconnect the heater hoses and the bypass hose.
  8.  
  9. Remove any vacuum hoses fitted to the manifold.
  10.  
  11. Remove the intake manifold bolts.
  12.  



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Fig. Removing the intake manifold assembly



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Fig. Intake manifold, throttle body and fuel rail assemblies

  1. Remove the manifold and throttle body from the engine as an assembly.
  2.  
  3. Remove the side and crossover gaskets.
  4.  
  5. Remove the plenum pan, if desired, by removing the bolts.
  6.  

To install:

  1. If the plenum pan was removed, use a new gasket. Tighten the bolts evenly and in a cross pattern beginning in the center of the plenum and working outward. Tighten bolts in three steps: to 24 inch lbs. (2.7 Nm), 48 inch lbs. (5.4 Nm), and 84 inch lbs.
  2.  



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Fig. The plenum pan bolt tightening sequence

  1. Place the plastic locator dowels (if supplied) in the engine block.
  2.  



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Fig. When applying the intake manifold end seals, line up their holes with the dowels and tangs

  1. Apply RTV sealant to the four corner joints. Bead height should be slightly higher than the crossover gaskets (about 0.2 in. or 5 mm)
  2.  



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Fig. Apply a small bead of sealant to the corners of the end seals



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Fig. Crossover gaskets and locator dowel holes-3.9L, 5.2L, and 5.9L gasoline engines

  1. Install the new front and rear crossover gaskets over the dowels.
  2.  
  3. Install the new flange gaskets on the cylinder heads.
  4.  


NOTE
Ensure that the vertical port alignment tab is resting on the deck face of the block and that the horizontal alignment tabs are in position with the mating cylinder head gasket tabs. The words MANIFOLD SIDE should be visible on the center of each flange gasket.

  1. Place the manifold into position on the engine block and cylinder heads.
  2.  
  3. Ensure that the gaskets have not shifted after the manifold is in place.
  4.  
  5. Install the intake manifold bolts, referring to the illustration, and tighten as follows:
  6.  

V6 Engine



Tighten bolts 1 and 2 to 72 inch lbs. (8 Nm), in alternating steps, 12 inch lbs. (1.4 Nm) at a time.
 
Tighten bolts 3 through 12 , in sequence, to 72 inch lbs. (8 Nm).
 
Finally, retighten all bolts, in sequence, to 12 ft. lbs. (16 Nm).
 



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Fig. Proper tightening sequence for the V6 intake manifold

V8 Engines



Referring to the appropriate illustration, tighten bolts 1 through 4 , in sequence, to 72 inch lbs. (8 Nm), in alternating steps, 12 inch lbs. (1.4 Nm) at a time.
 
Next, tighten bolts 5 through 12 , in sequence, to 72 inch lbs. (8 Nm).
 
Finally, retighten all bolts, in sequence, to 12 ft. lbs. (16 Nm).
 



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Fig. Proper tightening sequence for the V8 intake manifold

  1. Install the vacuum hoses in their proper locations.
  2.  
  3. Install the heater and bypass hoses.
  4.  
  5. Install the injector harness.
  6.  
  7. Install the fuel line(s).
  8.  
  9. Reconnect the emissions and throttle body sensor wiring.
  10.  
  11. Reconnect the throttle linkage, speed control cable (if equipped), and transmission kickdown cable (if equipped).
  12.  
  13. Reconnect the oil pressure sending unit.
  14.  
  15. Install the distributor cap.
  16.  
  17. Install the alternator.
  18.  
  19. Install the air cleaner assembly.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Fill and bleed the cooling system.
  24.  
  25. Check for leaks.
  26.  

4.7L Engine
  1. Disconnect the battery negative cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect the throttle and cruise control cables.
  6.  
  7. Disconnect the MAP, IAT, TPS, CTS and IAC sensors.
  8.  
  9. Disconnect the vapor purge, brake booster, speed control servo and PCV hoses.
  10.  
  11. Disconnect the alternator.
  12.  
  13. Disconnect the A/C electrical connectors.
  14.  
  15. Disconnect the left and right radio suppressor straps.
  16.  
  17. Disconnect and remove the ignition coil towers.
  18.  
  19. Remove the top oil dipstick tube retaining bolt and ground strap.
  20.  
  21. Bleed the fuel rail and remove it.
  22.  
  23. Remove the throttle body assembly and mounting bracket.
  24.  
  25. Drain the cooling system below manifold level.
  26.  
  27. Remove the heater hoses.
  28.  
  29. Remove the coolant temperature sensor.
  30.  
  31. Remove the manifold bolts and take off the manifold.
  32.  
  33. Installation is the reverse of removal. Tighten the manifold bolts gradually and in a cross pattern beginning in the center and working outwards. Proper torque is 105 inch lbs. (12 Nm).
  34.  



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Fig. Intake manifold tightening sequence -4.7L engine

8.0L Engine
  1. Drain the cooling system and disconnect the negative battery cable.
  2.  
  3. Remove the alternator and the air cleaner.
  4.  
  5. Remove the serpentine belt.
  6.  



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Fig. Details of the upper intake manifold and throttle body assembly-V-10 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. Details of the lower intake manifold-V-10 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 the accelerator linkage, and if so equipped, the speed control and transmission kickdown cables.
  6.  



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Fig. Exploded view of the lower intake manifold gaskets-V-10 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. Align the intake manifold flange gasket-V-10 engine

  1. Remove the closed crankcase ventilation and evaporation control systems.
  2.  
  3. Remove the 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 you are 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 installation, inspect to be sure all the gaskets and the seals are in their proper places. Finger-start all lower intake bolts.
  12.  
  13. Tighten all bolts, 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 Engines
  1. Disconnect the negative battery cables.
  2.  
  3. Remove the charge air cooler outlet tube from the air inlet housing.
  4.  
  5. Remove the engine oil dipstick mounting bolt and move the dipstick aside.
  6.  
  7. Disconnect the air grid heater power cables at the cable mounting studs.
  8.  
  9. Remove the four air inlet housing mounting bolts and remove the housing from top of the heater elements.
  10.  
  11. Remove the intake air grid heater from the manifold.
  12.  
  13. Remove the high pressure fuel lines.
  14.  
  15. Remove the rest of the manifold bolts and remove the manifold.
  16.  
  17. Installation is the reverse of removal. Tighten manifold bolts to 18 ft. lbs. (24 Nm).
  18.  



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Fig. Air inlet housing components-ground strap (1), air intake housing (2), heater power cable mounting studs (3), fuel bracket bolt (4), housing bolts (5)

 
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