OEM 2006 Dodge Sprinter 3500 Intake Manifold

2006 Dodge Sprinter 3500 Intake Manifold Parts and Q&A

• Q: How to Remove and Install an Intake Manifold on 2006 Dodge Sprinter 3500?

  A: Before disconnecting the intake manifold, disconnect the negative battery cable and drain some of the radiator's coolant so it does not exceed 90°C (194°F). Uncover the engine, then remove the lines where the fuel comes into the car, the fuel rail and the piece that supports it between cylinders #1 and #2. Disconnect the air hose at the intake, break the connection at the EGR harness and remove the bolt that holds the engine wiring harness to the intake manifold. Release the connection at the EGR valve on the coolant hose and at the fuel filter on both fuel lines. Taking out the lower intake manifold support bracket and setting up the vehicle so it's raised, you can now unscrew the rear intake manifold bolts from below. Remove all the remaining bolts to lower the intake manifold, guide the harness and fuel lines out while the intake sits free and then take out the old gasket. If removing and replacing the intake manifold, reinstall the EGR valve on the manifold with a brand new gasket. To fit the new manifold, remove dirt from both surfaces, set the gasket in the intake manifold and direct the wires and fuel lines through the manifold openings. Using a star pattern, tighten the bolts in the manifold to 16 Nm. Raise and support the vehicle, put in the rear intake manifold bolts and tighten to 16 Nm (142 inch lbs.), then install the lower intake manifold bracket and tighten the bolts to 20 Nm (177 inch lbs.). Put the vehicle down, attach the fuel pipe on each side to the fuel filter assembly and attach the coolant hose to the EGR valve. Fasten the engine wiring harness and cable duct to the intake manifold until the fastener measures 9 Nm (80 inch lbs.), then attach the EGR wiring harness connector and the fuel pressure sensor electrical connector. Connect the fuel rail to the engine, making sure you don't press down on the high pressure fuel lines during tightening and then attach the high pressure fuel lines and the charge air hose to the intake manifold. First, place on the hood cover, next fill the cooling system, third reconnect the negative side of the battery cable, turn on the engine to let it run until warmed up and then switch off the engine to inspect for any traces of fluid and check the fuel system warning while you check under the vehicle.