Ram Truck 1500, 2500 & 3500 (2006-2008)

Intake Manifold

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Removal & Installation



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-4.7L engines 3.7L similar

  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.  

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.  

5.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the charge air cooler outlet tube from the air inlet housing.
  6.  
  7. Remove the engine oil dipstick tube mounting bolt.
  8.  
  9. Remove dipstick support at fuel filter housing. Position dipstick tube to the side.
  10.  
  11. Disconnect the air grid heater power cables at the cable mounting studs.
  12.  
  13. Remove the engine wiring harness connections at the air inlet housing elbow.
  14.  
  15. Remove the four air inlet housing mounting bolts and remove the housing from top of the heater elements.
  16.  
  17. Remove the intake air grid heater from the manifold.

    Click image to see an enlarged view

    Fig. Intake air grid heater (1), gasket (2)

  18.  
  19. Remove the high pressure fuel lines and fuel rail.
  20.  
  21. Disconnect manifold air temperature/pressure sensor connector.
  22.  
  23. Remove the remaining intake manifold cover-to-cylinder head bolts.
  24.  
  25. Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air intake.
  26.  
  27. Clean the intake manifold cover and cylinder head sealing surface.
  28.  

To install:

  1. Using a new gasket, install the intake manifold cover.
  2.  
  3. Install the cover-to-cylinder head bolts that do not hold down the fuel rail. Tighten the bolts to 18 ft. lbs. (24 Nm).
  4.  
  5. Install the high pressure rail and fuel lines
  6.  
  7. Using two new gaskets, install the intake air grid heater and air inlet housing.
  8.  
  9. Connect the manifold air temperature/pressure sensor connector.
  10.  
  11. Install and tighten the air intake heater power supply nut to 120 inch lbs. (14 Nm).
  12.  
  13. Install oil dipstick tube support at fuel filter housing.
  14.  
  15. Install the engine oil dipstick tube and mounting bolt.
  16.  
  17. Position the charge air cooler outlet tube onto the air inlet housing. Tighten the clamps to 100 inch lbs. (11 Nm).
  18.  
  19. Attach the engine wire harness to the air inlet housing.
  20.  
  21. Prime the fuel system. Refer to the fuel priming procedure.
  22.  
  23. Connect the battery negative cables.
  24.  

6.7L Diesel Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the batteries.
  4.  
  5. Disconnect the EGR air transfer tube temperature sensor.
  6.  
  7. Disconnect the EGR valve actuator connector.
  8.  
  9. Disconnect the Engine Oil level tube at the Air Inlet bracket
  10.  
  11. Loosen and remove both v-band clamps at each end of the air transfer tube
  12.  
  13. Remove the P-clip mounting cap screw
  14.  
  15. Remove the air transfer tube.
  16.  
  17. Loosen and remove six air inlet mounting cap screws.
  18.  
  19. Remove the air inlet.
  20.  
  21. Remove the injector fuel lines.
  22.  
  23. Disconnect the fuel rail pressure sensor at the rear of the fuel rail manifold.
  24.  
  25. Remove the high pressure fuel line from the dump/overflow valve.
  26.  
  27. Remove the fuel rail.
  28.  
  29. Remove the grid heater wiring connector.
  30.  
  31. Disconnect the TMAP sensor.
  32.  
  33. Remove the intake manifold cap screws.
  34.  
  35. Remove the intake manifold.
  36.  

To install:

  1. Clean the intake manifold and cylinder head gasket area.
  2.  
  3. Install a new intake manifold gasket.
  4.  
  5. Position the intake manifold and Install the intake manifold cap screws finger tight.
  6.  
  7. Position the fuel rail and install the fuel rail manifold cap screws finger tight.
  8.  
  9. Tighten the intake manifold cap screws to 18 ft. lbs. (24 Nm).
  10.  
  11. Connect the fuel rail pressure sensor.
  12.  
  13. Connect the intake manifold grid heater. Torque the cap screw to 89 in. lbs. (10 Nm).
  14.  
  15. Install the fuel lines.
  16.  
  17. Tighten the fuel rail mounting cap screws to 18 ft. lbs. (24 Nm).
  18.  
  19. Clean the air inlet gasket area.
  20.  
  21. Clean the intake manifold to air inlet area.
  22.  
  23. Install the new air intake connection gasket.
  24.  
  25. Install the air intake connection to the intake manifold.
  26.  
  27. Tighten the intake manifold to 18 ft. lbs. (24 Nm).
  28.  
  29. Install the oil level gauge tube and torque to 18 ft. lbs. (24 Nm).
  30.  
  31. Clean the gasket area of the air transfer Tube (both ends).
  32.  
  33. Clean the EGR cooler and EGR control valve gasket area.
  34.  
  35. Using new gaskets, install the air transfer tube.
  36.  
  37. Install the V-band clamps.
  38.  
  39. Install the P-clip to the bracket. Torque the mounting cap screw to 18 ft. lbs. (24 Nm).
  40.  
  41. Tighten the V-band clamps to 89 lbs. in. (10 Nm).
  42.  
  43. Connect the EGR valve actuator connector.
  44.  
  45. Connect the EGR gas temperature connector.
  46.  
  47. Connect the batteries.
  48.  
  49. Start the engine and check for leaks.
  50.  

 
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