Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cables
     
    Intercooler outlet duct
     
    Dipstick tube
     
    Engine appearance cover
     
    Air inlet housing
     
    Exhaust Gas Recirculation (EGR) tube
     
    Fuel line assembly
     
    Air intake heater harness connectors

    Click image to see an enlarged view

    Fig. Intake air heater electrical connections-5.9L diesel engine

    Intake air heater electrical connections-5.9L diesel engine
     
    Charge air temperature sensor connector
     
    Accelerator pedal position sensor bracket
     
    Intake manifold cover
     

  4.  

To install:


NOTE
Use liquid Teflon® sealer on the intake manifold cover bolts.

  1. Install or connect the following:

    Intake manifold cover. Tighten the bolts to 18 ft. lbs. (24 Nm).
     
    Accelerator pedal position sensor bracket. Tighten the bracket to 32 ft. lbs. (43 Nm).
     
    Charge air temperature sensor connector
     
    Air intake heater harness connectors. Tighten the nuts to 10 ft. lbs. (14 Nm).
     
    Fuel line assembly
     
    Exhaust Gas Recirculation (EGR) tube
     
    Air inlet housing. Tighten the bolts to 18 ft. lbs. (24 Nm).
     
    Engine appearance cover
     
    Dipstick tube
     
    Intercooler outlet duct
     
    Negative battery cables
     

  2.  
  3. Start the engine and check for leaks.
  4.  

3.7L & 4.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Cruise control servo hose
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Engine ground straps
     
    Ignition coil towers
     
    Oil dipstick tube
     
    Fuel line
     
    Fuel supply manifold
     
    Throttle body and mounting bracket
     
    Cowl seal
     
    Right engine lifting stud
     
    Intake manifold. Remove the fasteners in reverse of the tightening sequence.
     

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.7 & 3.7L engines

Intake manifold torque sequence-3.7 & 3.7L engines

  1. Install or connect the following:

    Intake manifold using new gaskets. Torque the bolts, in sequence, to 105 inch lbs. (12 Nm).
     
    Right engine lifting stud
     
    Cowl seal
     
    Throttle body and mounting bracket
     
    Fuel supply manifold
     
    Fuel line
     
    Oil dipstick tube
     
    Ignition coil towers
     
    Engine ground straps
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Cruise control servo hose
     
    Brake booster vacuum line
     
    Canister purge vacuum line
     
    PCV valve and hose
     
    ECT sensor
     
    IAC valve connector
     
    TP sensor connector
     
    IAT sensor connector
     
    MAP sensor connector
     
    Cruise control cable
     
    Accelerator cable
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Fill and bleed the cooling system.
  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Alternator and A/C compressor bracket
     
    Air cleaner assembly
     
    Fuel line
     
    Fuel supply manifold
     
    Accelerator cable
     
    Transmission cable
     
    Cruise control cable
     
    Distributor cap and wires
     
    Ignition coil wiring
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hose
     
    Upper radiator hose
     
    Bypass hose
     
    Closed Crankcase Ventilation (CCV) system
     
    Evaporative emissions system
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.9L engine

Intake manifold torque sequence-3.9L engine

  1. Install the intake manifold. Use a new gasket and tighten the bolts in sequence as follows:
    1. Step 1: 48 inch lbs.
    2.  
    3. Step 2: 84 inch lbs.
    4.  
    5. Step 3: Recheck 84 inch lbs.
    6.  

  2.  
  3. Install or connect the following:

    Evaporative emissions system
     
    CCV system
     
    Bypass hose
     
    Upper radiator hose
     
    Heater hose
     
    ECT sensor connector
     
    Ignition coil wiring
     
    Distributor cap and wires
     
    Cruise control cable
     
    Transmission cable
     
    Accelerator cable
     
    Fuel supply manifold
     
    Fuel line
     
    Air cleaner assembly
     
    Alternator and A/C compressor bracket
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Alternator and A/C compressor bracket
     
    Air cleaner assembly
     
    Fuel line
     
    Fuel supply manifold
     
    Accelerator cable
     
    Transmission cable
     
    Cruise control cable
     
    Distributor cap and wires
     
    Ignition coil wiring
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hose
     
    Upper radiator hose
     
    Bypass hose
     
    Closed Crankcase Ventilation (CCV) system
     
    Evaporative emissions system
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.9L engine

Intake manifold torque sequence-3.9L engine

  1. Install the intake manifold. Use a new gasket and tighten the bolts in sequence as follows:
    1. Step 1: 48 inch lbs.
    2.  
    3. Step 2: 84 inch lbs.
    4.  
    5. Step 3: Recheck 84 inch lbs.
    6.  

  2.  
  3. Install or connect the following:

    Evaporative emissions system
     
    CCV system
     
    Bypass hose
     
    Upper radiator hose
     
    Heater hose
     
    ECT sensor connector
     
    Ignition coil wiring
     
    Distributor cap and wires
     
    Cruise control cable
     
    Transmission cable
     
    Accelerator cable
     
    Fuel supply manifold
     
    Fuel line
     
    Air cleaner assembly
     
    Alternator and A/C compressor bracket
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

5.2L & 5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Alternator and A/C compressor bracket
     
    Air cleaner assembly
     
    Fuel line
     
    Fuel supply manifold
     
    Accelerator cable
     
    Transmission cable
     
    Cruise control cable
     
    Distributor cap and wires
     
    Ignition coil wiring
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hose
     
    Upper radiator hose
     
    Bypass hose
     
    Closed Crankcase Ventilation (CCV) system
     
    Evaporative emissions system
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-5.2L and 5.9L engines

Intake manifold torque sequence-5.2L and 5.9L engines

  1. Install the intake manifold. Use a new gasket and tighten the bolts in sequence as follows:
    1. Step 1: 48 inch lbs.
    2.  
    3. Step 2: 84 inch lbs.
    4.  
    5. Step 3: Recheck 84 inch lbs.
    6.  
    7. Step 1: Bolts 1-4 to 72 inch lbs. (8 Nm) using 12 inch lb. (1.4 Nm) increments.
    8.  

  2.  
  3. Install or connect the following:

    Evaporative emissions system
     
    CCV system
     
    Bypass hose
     
    Upper radiator hose
     
    Heater hose
     
    ECT sensor connector
     
    Ignition coil wiring
     
    Distributor cap and wires
     
    Cruise control cable
     
    Transmission cable
     
    Accelerator cable
     
    Fuel supply manifold
     
    Fuel line
     
    Air cleaner assembly
     
    Alternator and A/C compressor bracket
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Alternator and A/C compressor bracket
     
    Air cleaner assembly
     
    Fuel line
     
    Fuel supply manifold
     
    Accelerator cable
     
    Transmission cable
     
    Cruise control cable
     
    Distributor cap and wires
     
    Ignition coil wiring
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Heater hose
     
    Upper radiator hose
     
    Bypass hose
     
    Closed Crankcase Ventilation (CCV) system
     
    Evaporative emissions system
     
    Intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-5.2L and 5.9L engines

Intake manifold torque sequence-5.2L and 5.9L engines

Click image to see an enlarged view

Fig. Intake manifold torque sequence-5.2L and 5.9L engines

Intake manifold torque sequence-5.2L and 5.9L engines

  1. Install the intake manifold. Use a new gasket and tighten the bolts in sequence as follows:
    1. Step 1: 48 inch lbs.
    2.  
    3. Step 2: 84 inch lbs.
    4.  
    5. Step 3: Recheck 84 inch lbs.
    6.  
    7. Step 1: Bolts 1-4 to 72 inch lbs. (8 Nm) using 12 inch lb. (1.4 Nm) increments.
    8.  

  2.  
  3. Install or connect the following:

    Evaporative emissions system
     
    CCV system
     
    Bypass hose
     
    Upper radiator hose
     
    Heater hose
     
    ECT sensor connector
     
    Ignition coil wiring
     
    Distributor cap and wires
     
    Cruise control cable
     
    Transmission cable
     
    Accelerator cable
     
    Fuel supply manifold
     
    Fuel line
     
    Air cleaner assembly
     
    Alternator and A/C compressor bracket
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accessory drive belt
     
    MAP connector
     
    IAT connector
     
    TPS connector
     
    CTS connector
     
    Brake booster hose
     
    PCV hose
     
    Alternator
     
    A/C compressor
     
    Intake manifold bolts, in a criss-cross pattern, from the outside to the center
     
    Intake manifold/IAFM
     

  8.  

To install:

  1. Position new intake manifold seals.
  2.  
  3. Install the intake manifold. Tighten the bolts in sequence from the center outwards, to 105 inch lbs. (12 Nm).
  4.  
  5. Install or connect the following:

    Electrical connectors
     
    Alternator
     
    A/C compressor
     
    Brake booster hose
     
    PCV hose
     
    Accessory drive belt
     
    Negative battery cable
     
    Air cleaner assembly
     

  6.  

8.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.

    Negative battery cable
     
    Accessory drive belt
     
    Alternator and brace
     
    A/C compressor and brace
     
    Air cleaner housing
     
    Fuel line
     
    Accelerator linkage
     
    cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Ignition coil pack and spark plug wires
     
    Intake manifold vacuum lines
     
    Engine control sensor harness connectors
     
    Heater hoses
     
    Bypass hose
     
    Evaporative Emissions (EVAP) system
     
    Closed Crankcase Ventilation (CCV) system
     
    Throttle body
     
    Upper intake manifold
     
    Lower intake manifold
     

  6.  

To install:

Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-8.0L engine

Upper intake manifold torque sequence-8.0L engine

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-8.0L engine

Lower intake manifold torque sequence-8.0L engine

  1. Install or connect the following:

    Lower intake manifold. Tighten the bolts in sequence to 40 ft. lbs. (54 Nm).
     
    Upper intake manifold. Tighten the bolts in sequence to 16 ft. lbs. (22 Nm).
     
    Throttle body. Tighten the bolts to 17 ft. lbs. (23 Nm).
     
    CCV system
     
    EVAP system
     
    Bypass hose
     
    Heater hoses
     
    Engine control sensor harness connectors
     
    Intake manifold vacuum lines
     
    Ignition coil pack and spark plug wires
     
    Transmission cable, if equipped
     
    cruise control cable, if equipped
     
    Accelerator linkage
     
    Fuel line
     
    Air cleaner housing
     
    A/C compressor and brace
     
    Alternator and brace
     
    Accessory drive belt
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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