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Intake Manifold: Installation

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the plenum pan was removed, position a new gasket and install the plenum pan (Fig 1 ). Tighten bolts in the following sequence:
    • Step 1. Tighten bolts to 5.4 N-m (48 in. lbs.)
    • Step 2. Tighten bolts to 9.5 N-m (84 in. lbs.)
    • Step 3. Check bolts to 9.5 N-m (84 in. lbs.)
    Fig 1: Identifying Plenum Pan Bolt Tightening Sequence
    G02656904Courtesy of DAIMLERCHRYSLER CORP.
  2. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs (Fig 2 ). The words MANIFOLD SIDE should be visible on the center of each flange gasket.
    Fig 2: Aligning Intake Manifold Flange Gasket
    G02656906Courtesy of DAIMLERCHRYSLER CORP.
  3. Apply Mopar(R) GEN II Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be approximately 5 mm (0.2 in) in diameter.
  4. Install the front and rear cross-over gaskets (Fig 3 ).
    Fig 3: Identifying Cross-Over Gaskets
    G02656905Courtesy of DAIMLERCHRYSLER CORP.
  5. Using a new gasket, install the throttle body onto the intake manifold (Refer to THROTTLE BODY ).
  6. Carefully lower intake manifold into position on the cylinder block and cylinder heads. After intake manifold is in place, inspect to make sure seals are in place.
  7. Install the intake manifold bolts and tighten as follows (Fig 4 ):
    • Step 1. Tighten bolts 1 and 2 to 8 N-m (72 in. lbs.) Tighten in alternating steps 1.4 N-m (12 in. lbs.) at a time
    • Step 2. Tighten bolts 3 through 12 to 8 N-m (72 in. lbs.)
    • Step 3. Check all bolts are torqued to 8 N-m (72 in. lbs.)
    • Step 4. Tighten all bolts in sequence to 16 N-m (12 ft. lbs.)
    • Step 5. Check all bolts are torqued to 16 N-m (12 ft. lbs.)
    Fig 4: Identifying Intake Manifold Bolt Tightening Sequence
    G02656907Courtesy of DAIMLERCHRYSLER CORP.
  8. Install closed crankcase ventilation and evaporation control systems.
  9. Connect the coil wires.
  10. Connect the heat indicator sending unit wire.
  11. Connect the heater hoses and bypass hose.
  12. Install distributor cap and wires.
  13. Hook up the return spring.
  14. Connect the accelerator linkage (Refer to THROTTLE CABLE ) and if so equipped, the speed control and transmission kickdown cables.
  15. Install the fuel lines (Refer to FUEL LINE DISCONNECT FITTINGS ).
  16. Install the accessory drive bracket and A/C Compressor (Refer to A/C COMPRESSOR ).
  17. Install the generator (Refer to GENERATOR ) and drive belt (Refer to DRIVE BELTS ).
  18. Install the air cleaner.
  19. Fill cooling system (Refer to STANDARD PROCEDURE-REFILLING COOLING SYSTEM 3.9L/5.9L ).
  20. Connect the negative cable to the battery.
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