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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 removed, position new plenum gasket and install plenum pan (Fig 1).
    Fig 1: Identifying Plenum Pan Bolt Tightening Sequence
    G02657210Courtesy of DAIMLERCHRYSLER CORP.
  2. Tighten plenum pan mounting bolts as follows:
    • 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 all bolts are at 9.5 N.m (84 in. lbs.)
  3. 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: Identifying Intake Manifold Flange Gasket
    G02657212Courtesy of DAIMLERCHRYSLER CORP.
  4. Apply Mopar® 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 and 15 mm (0.6 in.) long.
  5. Install the front and rear end seals (Fig 3) Make sure the molded dowel pins on the end seals fully enter the corresponding holes in the cylinder block.
    Fig 3: Identifying Front And Rear End Seals
    G02657211Courtesy of DAIMLERCHRYSLER CORP.
  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. Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 N.m (200 in. lbs.) torque.
  8. Install the intake manifold bolts and tighten as follows (Fig 4):
    • Step 1. Tighten bolts 1 through 4 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 5 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
    G02657213Courtesy of DAIMLERCHRYSLER CORP.
  9. Install closed crankcase ventilation and evaporation control systems.
  10. Connect the coil wires.
  11. Connect the heat indicator sending unit wire.
  12. Connect the heater hoses and bypass hose.
  13. Install distributor cap and wires.
  14. Hook up the return spring.
  15. Connect the accelerator linkage (Refer to THROTTLE CABLE ) and if so equipped, the speed control and transmission kick-down cables.
  16. Install the fuel lines (Refer to FUEL LINE DISCONNECT FITTINGS ).
  17. Install the accessory drive bracket and A/C compressor (Refer to A/C COMPRESSOR ).
  18. Install the generator and drive belt (Refer to DRIVE BELTS ). Tighten generator mounting bolt to 41 N.m (30 ft. lbs.) torque.
  19. Install the air cleaner.
  20. Fill cooling system (Refer to STANDARD PROCEDURE-REFILLING COOLING SYSTEM 3.9/5.9L ).
  21. Connect the negative cable to the battery.
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