Ram B1500, B2500, B3500, 1999-2003

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

     
    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

  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

  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

  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.  

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.  



Click image to see an enlarged view

Fig. Removing the intake manifold bolts



Click image to see an enlarged view

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.  



Click image to see an enlarged view

Fig. Removing the intake manifold assembly



Click image to see an enlarged view

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.  



Click image to see an enlarged view

Fig. The plenum pan bolt tightening sequence

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



Click image to see an enlarged view

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.  



Click image to see an enlarged view

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



Click image to see an enlarged view

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).
 



Click image to see an enlarged view

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).
 



Click image to see an enlarged view

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.  



Click image to see an enlarged view

Fig. Intake manifold tightening sequence -4.7L engine

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

  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



Click image to see an enlarged view

Fig. 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



Click image to see an enlarged view

Fig. 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.  

  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.  



Click image to see an enlarged view

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.  



Click image to see an enlarged view

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.  



Click image to see an enlarged view

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.  



Click image to see an enlarged view

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.  

 
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