Manifold-Intake Vacuum Port Repair
WARNING: This page is about a different car, the 2008 Dodge Magnum, 2008 Dodge Charger, and 2008 Chrysler 300. 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 Nipple - 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 (2) base using a 7/16" drill bit.
- Using a 1/4"-18 NPT pipe tap (1), cut internal threads. 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).