Chrysler RAM50/D50/Arrow 1979-1993 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



2.0L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system. Disconnect the upper radiator hose at the thermostat housing.
  4.  


CAUTION
When 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. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the carburetor. This will involve the removal or repositioning of several hoses, lines and wires. Make sure each is properly labeled so it may be reinstalled correctly.
  2.  



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Fig. Fig. 1: Apply sealant on these points of the intake manifold gasket before installation

  1. Disconnect any remaining vacuum lines and on some models, EGR system piping.
  2.  
  3. Remove all the intake manifold retaining nuts and washers. These may be difficult to break loose. Use rust penetrate freely and keep the wrench square on the bolt to prevent breakage. Gently tap the manifold loose from the gaskets with a rubber or plastic mallet, and remove it.
  4.  

To install:
  1. If a new manifold is being installed, transfer parts such as the thermostat and gasket, and any vacuum fittings. Thoroughly clean the sealing surfaces of the cylinder head and, if it's being re-used, the manifold. Check the cylinder head and manifold sealing surfaces for flatness with a straightedge. Correct a warped surface by replacing the manifold or having the cylinder head surface machined. Install new gasket(s) against the head. Make sure all bolt holes and passages for the cooling water and intake ports align properly.
  2.  
  3. Position the manifold against the gasket and support it there while installing washers and nuts finger-tight. Tighten the bolts evenly and in at least two passes to 15 ft. lbs. (22 Nm).
  4.  
  5. Install the carburetor assembly and all hoses, wires and vacuum lines.
  6.  
  7. Refill the coolant. Connect the negative battery cable. Start the engine and check carefully for leaks of either coolant or vacuum.
  8.  

2.4L Engine See Figure 2

  1. Relieve the fuel pressure by disconnecting the wiring to the electric fuel pump, located back by the fuel pump. Start the vehicle and let it run until it stalls on its own. Turn the vehicle OFF .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant. Disconnect the upper radiator hose from the thermostat housing.
  6.  
  7. Remove the air intake hoses, breather hose and the air intake pipe.
  8.  
  9. Disconnect all wires, hoses and linkages to the throttle body.
  10.  



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Fig. Fig. 2: Throttle body and air intake plenum assemblies and components-2.4L engines

  1. Disconnect the ignition coil high tension cable from the distributor.
  2.  
  3. Disconnect the brake booster hose and vacuum hose cluster from the air intake plenum.
  4.  
  5. Unbolt the air intake plenum from the intake manifold and remove the plenum from the engine.
  6.  
  7. Cover the fuel line with a clean shop rag and disconnect the fuel lines from the fuel rail. Keep the line covered or plugged.
  8.  
  9. Remove and label the fuel injector harness connectors. Make sure to retrieve the injector insulator washers, these will have to be replaced upon reinstallation.
  10.  
  11. Remove the fuel rail assembly with injectors intact.
  12.  
  13. Disconnect the heater hose from the manifold.
  14.  
  15. Disconnect the wires to the engine coolant switches.
  16.  
  17. Remove the distributor. Refer to the previously described procedure in this section.
  18.  
  19. Unbolt the intake manifold from the cylinder head and remove from the engine.
  20.  
  21. Clean and dry the mating surfaces of the manifold and cylinder head.
  22.  

To install:
  1. Using a new gasket, install the intake manifold to the head. Starting from the middle and working outward, tighten the retaining nuts to 12 ft. lbs. (16 Nm).
  2.  
  3. Connect the wires to the engine coolant switches. Install the distributor with matchmarks aligned.
  4.  
  5. Install the fuel rail assembly to the manifold and connect the fuel line using a new O-ring.
  6.  
  7. Connect the heater hose to the manifold.
  8.  
  9. Install the air intake plenum with a new gasket. Tighten the retaining bolts to 12 ft. lbs. (16 Nm).
  10.  
  11. Connect the vacuum hoses cluster, brake booster hose and all wires, hoses and linkages to the throttle body.
  12.  
  13. Install the ignition coil.
  14.  
  15. Install the air intake pipe and hoses.
  16.  
  17. Connect the upper radiator hose.
  18.  
  19. Fill the radiator with coolant.
  20.  
  21. Connect the negative battery cable and connect the jumper wire from the fuel pump activation terminal to the positive battery post to inspect the system for leaks.
  22.  
  23. Set all adjustments to specifications.
  24.  

2.6L Engine See Figures 3 through 8

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly from the carburetor.
  4.  
  5. Drain the coolant. Disconnect the upper radiator hose at the thermostat housing.
  6.  


CAUTION
When 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. Coolant should be reused unless it is contaminated or several years old.



Click image to see an enlarged view

Fig. Fig. 3: Intake manifold assembly - 2.6L engine.



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Fig. Fig. 4: Label and remove all hoses attached to the intake manifold.

  1. Remove the carburetor assembly. This will involve the removal or repositioning of several hoses, lines and wires. Make sure each is properly labeled so that it may be reinstalled correctly.
  2.  
  3. Remove the water outlet fitting, the thermostat and the gasket.
  4.  
  5. Remove the secondary air cleaner assembly and the secondary air pipe.
  6.  
  7. If necessary, disconnect the bolt holding the engine oil dipstick tube and remove the tube and dipstick. Don't lose the O-ring on the tube.
  8.  
  9. If necessary, loosen the adjuster for the air conditioning compressor belt and remove the belt from the compressor. Disconnect the wire to the compressor. Remove the bolts holding the compressor to its mounting bracket and move the compressor (with the lines attached) out of the way. Support from a piece of stiff wire.
  10.  


WARNING
Do not loosen any air conditioning lines or discharge the system.

  1. Remove the compressor bracket from the engine.
  2.  
  3. Disconnect the heater hose at the manifold.
  4.  
  5. Disconnect the brake booster vacuum hose at the manifold.
  6.  



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Fig. Fig. 5: Remove the manifold retaining nuts and bolt



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Fig. Fig. 6: Pull the intake manifold off the side of the cylinder head

  1. Disconnect the small water hose at the rear of the manifold.
  2.  
  3. Disconnect the wiring and retainers running to the manifold. Check carefully for concealed wires underneath.
  4.  
  5. Remove the EGR valve. Discard the gasket; it is not reusable.
  6.  
  7. Label and disconnect the vacuum hoses from the thermo valve at the thermostat housing.
  8.  
  9. Loosen the nuts and bolt holding the manifold to the engine. Support the manifold and remove it.
  10.  

To install:
  1. Thoroughly clean the sealing surfaces of the cylinder head and the manifold. Check the cylinder head and manifold sealing surfaces for flatness with a straightedge. Correct a warped surface by replacing the manifold or having the cylinder head surface machined. If the manifold is to be replaced, each fitting and sensor must be removed and transferred to the new unit. Note that when the thermo-vacuum valve is transferred, it must be sealed with a waterproof sealer such as 3M 4171 or equivalent. The new manifold should be completely equipped with its supply of sensors, vacuum ports and fittings before installation.
  2.  
  3. Install new gasket(s) against the head. Make sure all bolt holes and passages for the cooling water and intake ports align properly.
  4.  
  5. Install the manifold and retaining nuts and bolt. Tighten the hardware finger-tight.
  6.  



Click image to see an enlarged view

Fig. Fig. 7: Never reuse an old gasket, leaking will occur.



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Fig. Fig. 8: Old gasket material must be completely removed from the manifold mating surface

  1. Working from the center of the manifold outward, tighten the nuts and bolt to 15 ft. lbs. (22 Nm) in at least 2 stages.
  2.  
  3. Install the EGR valve with a new gasket.
  4.  
  5. Connect the vacuum hoses to the thermo-vacuum valve. Connect the wiring to each sensor or switch on the manifold. Make certain that the wires are connected to the correct unit. Install any cable clamps which were removed.
  6.  
  7. Install the small water hose to the back of the manifold.
  8.  
  9. Connect the brake booster vacuum hose.
  10.  
  11. Install the compressor bracket to the engine, tightening the bolts to 33 ft. lbs. (45 Nm).
  12.  
  13. Install the compressor, tightening the bolts to 18 ft. lbs. (24 Nm). Connect the wire to the compressor and install the belt. Tighten the belt adjuster to draw the correct tension on the belt.
  14.  
  15. Install the oil dipstick and tube. Make certain the tube is secure in the engine.
  16.  
  17. Install the secondary air tube and secondary air cleaner assembly.
  18.  
  19. Install the thermostat with a new gasket and sealer; install the water outlet. Tighten the bolts no more than 9 ft. lbs. (12 Nm).
  20.  
  21. Install the carburetor assembly with a new gasket.
  22.  
  23. Install the air cleaner assembly.
  24.  
  25. Refill the coolant and connect the negative battery cable.
  26.  
  27. Start the engine and check for leaks of coolant, oil or vacuum. Confirm the proper operation of all electrical lights and gauges on the dashboard. Turn on the air conditioning and confirm the compressor's operation.
  28.  

 
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