OEM Dodge Ram 1500 Van Intake Manifold

Dodge Ram 1500 Van Intake Manifold Parts and Q&A

• Intake Manifold
  4897490AC
  Q: How to service and repair the intake manifold on Dodge Ram 1500 Van?

  A:

  To service the intake manifold, disconnect the negative battery cable, take off the engine cover, empty the cooling system, remove the A/C compressor, generator, accessory drive bracket and air cleaner. Release pressure in the fuel system and then take off the fuel line connections. After that, unfasten the accelerator linkage, the speed control and the transmission kickdown if available, then remove the return spring, distributor cap and wires, coil wires, heat indicator sending unit wire, heater hoses and bypass hose. Disconnect the crankcase ventilation and evaporation control, remove the bolts from the intake manifold and take the manifold and throttle body out altogether. Throw away the gaskets along the flange sides and both cross-overs and then take out the throttle body. If you need to, remove the plenum pan and throw away the gasket. After cleaning the manifold with a solvent, dry it with compressed air so that both front and rear faces of the cylinder block gaskets are tidy. Check the manifold for any signs of cracks and use a straightedge to see if the mating surfaces are not warped. If you took out the plenum pan, put in a new gasket and install it, initially tightening the bolts to 5.4 Nm (48 in. lbs.), then to 9.5 Nm (84 in. lbs.) and confirm the last measurement is 9.5 Nm (84 in. lbs.). Position the flange gaskets so that the vertical port alignment tab lines up with the block's face, the horizontal tabs with the cylinder head gasket's tabs and on each gasket, the words Manifold Side can be seen. Put some Mopar Gen Ii Silicone Rubber Adhesive Sealant or another equivalent, around the four corners, making sure the sealant is about 5 mm (0.2 in.) in diameter. Place the front and rear cross-over gaskets first and finalize the job with the brand-new throttle body onto the intake manifold. Set the intake manifold down on the cylinder block and cylinder heads after checking that all the seals are in place. First, tighten bolts 1 and 2 with 8 Nm (72 in. lbs.), alternating each tightening by 1.4 Nm (12 in. lbs.,) then tighten bolts 3 through 12 to 8 Nm (72 in. lbs.) and carefully tighten all bolts to 16 Nm (12 ft. lbs.) in sequence. Put back the closed crankcase ventilation and evaporation control systems, attach the coil wires, heat indicator wire, heat hoses, bypass hose, distributor cap and wires and mechanical return spring. After that, connect the accelerator linkage, speed control and transmission kickdown cables. Attach the fuel lines, accessory drive bracket, A/C compressor, generator and drive belt, then go on to the air cleaner. Add coolant to the coolant system, install the cover on the engine and hook up the battery's negative cable.
• Intake Manifold
  4897489AB
  Q: How to remove and install the intake manifold on Dodge Ram 1500 Van?

  A:

  Unhook the battery's negative cable from the battery and let any remaining coolant drain before you proceed. After that, take out the A/c compressor, generator and accessory drive bracket and then the air cleaner. Drop the fuel system pressure and disconnect the fuel tubes. Unplug all accelerator linkage, speed control and transmission kickdown cables if they exist and then take out the return spring. Remove the distributor cap and its wires, separate the coil wires, your car's heater sensor wire and the hoses for your heater and bypass part. Uninstall the crankcase ventilation and evaporation control parts, take off the intake manifold bolts and lift everything out together. Dispose of the flange side gasket, as well as the front and rear crossover gaskets and detach and throw away the throttle body and plenum pan gasket if this step is not obsolete. If installation calls for removing the plenum pan and gasket, put the new gasket under the pan, secure the pan and tighten the bolts to 5.4 Nm (48 in. lbs.), then to 9.5 Nm (84 in. lbs.) and recheck to the same torque. Secure the throttle body onto the intake manifold using a new gasket and then use Mopar Gen Ii Silicone Rubber Adhesive Sealant to seal the four joints on each corner. First, install the cross-over gaskets in the front and rear, then secure the flange gaskets, so that the cylinder head gasket tabs are lined up correctly and the words Manifold Side are facing you on both. Place the intake manifold down into position on the cylinder block and heads using the alignment dowels included in the cross-over gaskets. Then, inspect if all seals have been positioned correctly. Put in the intake manifold bolts and tighten them up, then once more install the closed crankcase ventilation and evaporation control systems, connect the coil wires, the heat indicator sending unit wire, the heater hoses and the bypass hose. After that, reinstall the distributor cap and wires, hook up the return spring and attach the accelerator linkage plus the speed control and transmission kickdown cables if your car has them. Installing the fuel lines, accessory drive bracket, A/c compressor, generator and drive belt should be done and the generator mounting bolt tightened to 41 Nm (30 ft. lbs.). After that, attach the air cleaner, charge the cooling system and reattach the negative cable to the battery.