OEM 2003 Dodge Sprinter 3500 Intake Manifold

2003 Dodge Sprinter 3500 Intake Manifold Parts and Q&A

• Q: How to Remove and Install an Intake Manifold on 2003 Dodge Sprinter 3500?

  A: The intake manifold should first be disconnected from the battery cable and drained before anything else. Take out the engine cover, unplug the wiring harness inside the vehicle and guide it into the engine compartment. Remove the charge air hose and the EGR connectors and next remove the bolt that holds the engine wiring harness to the intake manifold. Coolant should be drained by removing the hose at the junction point under the intake manifold support bracket and correcting any spills. Then, unplug both fuel lines from the fuel filter and take out the lower and right intake manifold support brackets. Unplug the connector of the fuel pressure sensor, lift and prop up the vehicle and then take out the rear coolant hose from the intake manifold. While you can reach the family-car rear intake mounting bolts, remove them on the underside, then lower the car to work on the additional ones. Raise the intake manifold overall, leading the engine wiring and fuel lines out through the openings as you do so and then remove the gasket. Clean both surfaces that fit together and then fix a new intake manifold gasket on the intake manifold, passing the wires and fuel hoses through its openings to install. Fasten the manifold bolts to 16 Nm (142 inch lbs.) in the pattern shown below, by fastening the center ones first. With the vehicle lifted, install the rear intake manifold bolts and tighten them to 16 Nm (142 inch lbs.), after that safely place the rear coolant hose onto the intake manifold and secure with a tightening clamp. Place the vehicle on lower stand, fit the electrical connector for fuel pressure sensor, add the right intake manifold support brackets and tighten bolts to 14 Nm (124 inch lbs.); then install the lower intake manifold, tighten bolts to 20 Nm (177 inch lbs.). Connect both fuel lines where they enter the fuel filter assembly, join the coolant hose with the other above the bottom intake manifold support, secure the engine wiring harness and cable duct to the intake manifold, attach the EGR wiring harness connector and place the charge air hose onto the intake manifold. Pass the engine wiring harness through the firewall and return it to the passenger area, reconnecting it, then attach the engine cover, fill the coolant tank, readd the battery negative cable and power on the engine to look for leaks and check the fuel system warning signal.