OEM 2002 Dodge Ram 3500 Intake Manifold

2002 Dodge Ram 3500 Intake Manifold Parts and Q&A

• Q: How to Service and Repair an Intake Manifold on 2002 Dodge Ram 3500?

  A: The first step in working on the intake manifold is to remove both the negative battery cables. Take out the charge air cooler outlet tube from the air inlet housing and the engine oil dipstick tube mounting bolt, then place the dipstick tube beside the engine. Unscrew the heater power cables from the wall studs and then untight the four bolts on the air inlet housing to remove the housing over the elements. Then, eliminate the intake air grid heater from the manifold, plus the high pressure fuel lines and the rest of the bolts from the manifold to cylinder head. Remove the intake manifold cover and gasket slowly, so the gasket material and all debris get kept out of the air intake, after which you should clean the intake manifold cover and the area of the cylinder head that it seals to. Spray the manifold with solvent, dry it with compressed air and wash the front and rear gasket areas of the cylinder block with a suitable cleaner, keeping the plenum pan rail clean as well. Look for cracks in the manifold and use a straightedge to ensure the surfaces where it connects to the cylinder head are flat. While installing, put a new gasket between the intake manifold cover and the cylinder head, then adjust the cover-to-cylinder head bolts not connected to the high pressure fuel line support brackets to 24 Nm (18 ft. lbs.) torque. Set up the high pressure fuel lines and bolt the high pressure line support bracket to the cover on the intake manifold, making sure they're secure after tightening to 24 Nm (18 ft. lbs.). With the new gaskets in position, connect the intake air grid heater and the air inlet housing, snapping the ground cable in place and set the torque for the bolts to 24 Nm (18 ft. lbs.). Attach the air intake heater supply nuts with 14 Nm (120 inch lbs.) of torque and place the engine oil dipstick tube and mounting bolt at this time as well. Put the charge air cooler outlet tube next to the air inlet housing and tighten the clamps to 8 Nm (72 inch lbs.). You should finish by bleeding the fuel air system and reattaching the negative cables to the battery after all tests are done.