Chrysler Full-Size Vans 1989-1998 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12

  1. Properly relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the alternator.
  6.  
  7. Remove the distributor.
  8.  
  9. Label and disconnect the oil pressure sending unit.
  10.  
  11. Label and disconnect the intake air temperature sensor.
  12.  
  13. Disconnect the accelerator linkage, speed control cable (if equipped), and transmission kickdown cable (if equipped).
  14.  
  15. Label and disconnect the MAP sensor, IAC motor, and TP sensor (if equipped) on the throttle body.
  16.  
  17. Disconnect the fuel line(s).
  18.  
  19. Label and disconnect the injector harness and secure it out of the way.
  20.  
  21. Label and disconnect the heater and bypass hoses.
  22.  
  23. Label and disconnect the vacuum hoses from the intake manifold.
  24.  
  25. If necessary, remove the passenger side valve cover.
  26.  
  27. Remove the manifold retaining bolts.
  28.  
  29. Lift the manifold and throttle body off the engine as an assembly.
  30.  
  31. Remove the plenum pan (if necessary) as follows:
    1. Turn the manifold upside down.
    2.  
    3. Remove the retaining bolts on the plenum pan, and lift the pan off the manifold.
    4.  

  32.  



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Fig. Fig. 1: Label and disconnect any components and harnesses necessary to remove the intake manifold



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Fig. Fig. 2: Remove and label any vacuum lines necessary for intake manifold removal



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Fig. Fig. 3: Loosen the intake manifold retaining bolts



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Fig. Fig. 4: Lift the intake manifold off the cylinder heads and engine block



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Fig. Fig. 5: Remove the old flange gaskets ...



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Fig. Fig. 6: ... and the old end seals



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Fig. Fig. 7: The intake manifold can be removed from the vehicle as an assembly

To install:


Clean the manifold, cylinder head and engine block gasket mating surfaces thoroughly.
 
If the plenum pan was removed, install it as follows:
 

  1. Turn the manifold upside down.
  2.  
  3. Place a new plenum pan gasket onto the seal rails of the manifold.
  4.  
  5. Position the pan over the gasket and align the pan holes with those on the manifold.
  6.  
  7. Hand-start the bolts.
  8.  
  9. Tighten the bolts in the proper sequence as follows:

    Tighten the bolts to-24 inch lbs. (2.7 Nm).
     
    Tighten the bolts to-48 inch lbs. (5.4 Nm).
     
    Tighten the bolts to-84 inch lbs. (9.5 Nm).
     

  10.  



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Fig. Fig. 8: The plenum pan bolt tightening sequence

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



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Fig. Fig. 9: 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.
  2.  



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Fig. Fig. 10: Apply a small bead of sealant to the corners of the end seals

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

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 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).
 
Tighten all bolts, in sequence, to 12 ft. lbs. (16 Nm).
 



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Fig. Fig. 11: Proper tightening sequence for the V6 intake manifold

V8 Engines


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.
 
Tighten bolts 5 through 12, in sequence, to 72 inch lbs. (8 Nm).
 
Tighten all bolts, in sequence to 12 ft. lbs. (16 Nm).
 



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Fig. Fig. 12: Proper tightening sequence for the V8 intake manifold

  1. Install the passenger side valve cover (if removed).
  2.  
  3. Install the vacuum hoses in their proper locations.
  4.  
  5. Install the heater and bypass hoses.
  6.  
  7. Install the injector harness.
  8.  
  9. Install the fuel line(s).
  10.  
  11. Reconnect the MAP sensor, IAC motor, and TP sensor.
  12.  
  13. Reconnect the accelerator linkage, speed control cable (if equipped), and transmission kickdown cable (if equipped).
  14.  
  15. Reconnect the intake air temperature sensor.
  16.  
  17. Reconnect the oil pressure sending unit.
  18.  
  19. Install the distributor.
  20.  
  21. Install the alternator.
  22.  
  23. Install the air cleaner assembly.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Check the engine oil level.
  28.  


WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  1. Fill and bleed the cooling system.
  2.  
  3. Check for leaks.
  4.  
  5. Install the engine cover.
  6.  

 
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