Standard Procedure - Intake Manifold Vacuum Port Repair
WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
The composite intake manifold vacuum ports can be repaired. Although, if the manifold plenum chamber is damaged or cracked, the manifold must be replaced.
To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following procedure:
| PARTS REQUIRED | TOOLS REQUIRED |
| Brass Nipple - 3/8" O.D. x 1/4" pipe thread (Speed Control Port) | Pipe Tap - 1/4" - 18 NPT |
| Brass Nibble - 1/2" O.D. x 1/4" pipe thread (Brake Booster Port) | Drill Bit - 7/16" |
| File/Sand Paper |
NOTE:
While performing this procedure, avoid getting the manifold material residue into the plenum chamber.
- File or sand the remaining port back until a flat surface is obtained (plane normal to nipple (port) axis).
- Drill out the nipple (port) base using a 7/16" drill bit. See Fig 1.
- Using a 1/4"-18 NPT pipe tap, cut internal threads. See Fig 1. Use caution to start tap in a axis same as original nipple.
- Apply Mopar® Thread Sealant to threads of repair nipple(s).
- Install repair nipple(s). Do not over torque repair nipple(s).
| 1 - 1/4" - 18NPT PIPE TAP |
| 2 - NIPPLE (PORT) |