Chrysler Full-Size Vans 1967-1988 Repair Guide

Intake Manifold

Print

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10

Click image to see an enlarged view

Fig. Fig. 1: Intake manifold side gasket for the 238 engine-left side shown



Click image to see an enlarged view

Fig. Fig. 2: Intake manifold end seal installation for the 238 engine



Click image to see an enlarged view

Fig. Fig. 3: Intake manifold torque sequence for the 238 engine



Click image to see an enlarged view

Fig. Fig. 4: Intake manifold side gasket for the 318 and 360 engines-left side shown



Click image to see an enlarged view

Fig. Fig. 5: Intake manifold end seal installation for the 318 and 360 engines



Click image to see an enlarged view

Fig. Fig. 6: Intake manifold torque sequence for the V8 engine



Click image to see an enlarged view

Fig. Fig. 7: For intake removal on V8 engines, label and remove all hoses, wires, and attaching bolts



Click image to see an enlarged view

Fig. Fig. 8: Remove the intake manifold as an assembly with the carburetor installed



Click image to see an enlarged view

Fig. Fig. 9: Remove the old intake gasket side seals ...



Click image to see an enlarged view

Fig. Fig. 10: ... and the end seals then, clean all gasket mating surfaces

V6 and V8 Engines

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


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Coolant should be reused unless it is contaminated or several years old.

  1. Remove alternator, carburetor air cleaner and fuel line.
  2.  
  3. Disconnect accelerator linkage.
  4.  
  5. Remove vacuum hose between carburetor and distributor.
  6.  
  7. Remove the distributor cap and wires.
  8.  
  9. Disconnect coil wires, temperature sending unit wire, heater hoses and bypass hose.
  10.  
  11. Remove intake manifold, ignition coil and carburetor as an assembly.
  12.  
  13. Installation is the reverse of the above procedure. Tighten the intake manifold to head bolts in the sequence illustrated, from center alternating out.
  14.  
  15. Tighten the exhaust manifold mounting nuts to the required torque which is listed in the specifications chart of this section.
  16.  

Diesel Engine

  1. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the battery ground cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Disconnect the fuel lines at the fuel filter, transfer pump and injection pump. See Fuel System .
  6.  
  7. Drain the fuel filter and remove it from the back of the manifold. See General Information And Maintenance .
  8.  
  9. Remove the manifold and air cleaner mounting bracket bolts.
  10.  
  11. Disconnect the injection lines at the injection pump and remove the nozzle holder from the cylinder head. See Fuel System .
  12.  
  13. Remove the fuel line clamps from the manifold and push the fuel lines up and out of the way.
  14.  
  15. Remove the manifold and gaskets from the head.
  16.  
  17. Install the manifold and new gaskets on the head.
  18.  
  19. Install the fuel lines and clamps on the manifold.
  20.  
  21. Connect the injection lines at the injection pump.
  22.  
  23. Install the nozzle holder on the cylinder head. See Fuel System
  24.  
  25. Install the manifold and air cleaner mounting bracket bolts.
  26.  
  27. Install the fuel filter on the back of the manifold. See General Information & Maintenance .
  28.  
  29. Connect the fuel lines at the fuel filter, transfer pump and injection pump. See Fuel System .
  30.  
  31. Install the air cleaner.
  32.  
  33. Connect the battery ground cable.
  34.  
  35. Fill the cooling system.
  36.  

 
label.common.footer.alt.autozoneLogo