OEM 2005 Dodge Ram 3500 Intake Manifold

2005 Dodge Ram 3500 Intake Manifold Parts and Q&A

• Q: How to Service an Intake Manifold on 2005 Dodge Ram 3500?

  A: The intake manifold should be serviced by disconnecting the negative cables from the battery first. Remove the charge air cooler outlet hose from the air inlet housing, the bolt and the support for the engine oil dipstick, then move the dipstick tube to the edge of the housing. Unplug the end of the air grid heater's power cables at the connecting studs and disconnect the engine's wiring from the air inlet housing elbow. Watch next for how to remove the four air inlet housing mounting bolts and remove the housing on top of the heater elements. Take out the intake air grid heater, the two lines responsible for supplying high pressure fuel and the fuel rail and after that separate the manifold air pressure/temperature sensor connector. Remove all the remaining bolts securing the intake manifold to the cylinder head and lift away the cover and gasket, ensuring you don't let any material enter the air intake tube underneath. Wash and dry the engine's manifold cover, cylinder head gasket sealing surface, gasket surfaces for the manifold and cylinder block and the plenum pan rail. Examine the manifold for signs of damage and straighten the mating surfaces with a gauge smooth it out. To mount the intake manifold cover, apply a new gasket and screw in the cover-to-cylinder head bolts that do not support the fuel rail, tightening them to 18 ft. lbs. The bolts holding the fuel line should not be tightened yet. Set up the high pressure pipe and fuel lines after that; then use the new gaskets to secure the intake air grid heater and air inlet housing. Plug the manifold air temperature/pressure sensor according to instructions and secure the air intake heater power supply nuts to 14 Nm (120 inch lbs.) torque. Fit the oil dipstick tube support to the fuel filter housing and then install the engine oil dipstick tube and mounting bolt. Connect the outlet end of the charge air cooler to the air inlet housing and close the clamps until you reach a torque of 11 Nm (100 inch lbs.). At two points, attach the engine wire harness to the air inlet housing, fill the fuel primer and reattach the negative cable that goes to the battery.