INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD
1. Perform fuel system pressure release procedure (Refer to 14 - FUEL SYSTEM - STANDARD PROCEDURE).
2. Drain the cooling system.
3. Remove the upper intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
4. Remove the fuel line (4) (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE).
5. Remove ignition coil and bracket.
6. Disconnect heater supply hose and engine coolant temperature sensor.
7. Disconnect the fuel injector wire harness.
8. Remove the fuel injectors and rail assembly (3) (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
9. Remove radiator upper hose.
10. Remove the intake manifold bolts.
11. Remove lower intake manifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.
12. Remove intake manifold seal retainers screws. Remove intake manifold gasket.
CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.
INSPECTION
Check for:
- Damage and cracks of each section.
- Clogged water passages in end cross-overs (if equipped).
- Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. (Refer to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
INSTALLATION - LOWER INTAKE MANIFOLD
1. Place a bead (approximately 1/4 in. diameter) of Mopar® Engine RTV GEN II onto each of the four manifold to cylinder head gasket corners (1).
2. Carefully install the new intake manifold gasket. Tighten end seal retainer screws to 12 N·m (105 in. lbs.).
3. Install lower intake manifold. Install the bolts and torque to 1 N·m (10 in. lbs.). Then torque bolts to 22 N·m (200 in. lbs.) in sequence shown. Then torque again to 22 N·m (200 in. lbs.). After intake manifold is in place, inspect to make sure seals are in place.
4. Install the fuel injectors and rail assembly (3) (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - INSTALLATION).
5. Connect fuel injector electrical harness.
6. Connect the engine coolant temperature sensor.
7. Connect the heater supply and radiator upper hoses to manifold.
8. Connect the fuel line (4) (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE).
9. Install the upper intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).
10. Connect negative battery cable.
11. Fill the cooling system.
12. Connect the negative battery cable.