Attention! Since 1996, a separate upper intake manifold has been installed on engines. On all engines except V8 7.4 liters, the manifold is removed as an assembly (the upper and lower parts of the collector are removed together). On V8 7.4L engines, the upper intake manifold is removed first.
1. Disconnect the battery from the ground, drain the liquid from the cooling system. On models from 1996 with a 7.4L V8 engine, remove the upper intake manifold first (see below).
2. Remove the air filter. If the manifold is removed for grinding the split plane or for replacement, then also remove the throttle (see Chapter 4).
3. On parts of cars, remove the alternator rear bracket (see photo). On models with air conditioning, disconnect the air conditioner brackets and move it to the side.
4. Remove ESC bracket from manifold (see photo). Remove the tensioner pulley bracket.
5. Designate and disconnect from an inlet collector all fuel pipes and hoses, wires and vacuum hoses. Depending on the type of engine, year and body, it may be necessary to remove other parts mounted on the intake manifold.
6. Disconnect the upper radiator hose and heater hose from the thermostat housing cover (see photo).
7. Remove the ignition distributor and ignition coil wires (Chapter 5).
8. Gradually, 1/4 turn per reception, loosen the mounting bolts so that they can be unscrewed by hand. The manifold usually sticks to the cylinder head. Pry off the front of the manifold with a pry bar inserted under the cylinder head boss next to the thermostat housing.
Attention! It is not allowed to rest the tool between the cylinder block and the manifold, or the cylinder heads and the manifold, otherwise the split surface will be damaged, which will lead to a decrease in the vacuum in the manifold.
Attention! The split planes of the head and cylinder block and manifold must be perfectly clean. It is recommended to use a solvent for old seals for cleaning.
9. Clean the manifold and split planes on the head and manifold. Cover the openings under the pushers with a rag to prevent dirt from entering (see photo).
10. Drive the threads of the manifold holes and blow them out with compressed air (see photo).
11. Apply a thin coat of RTV Sealant (see photo) around the holes in the new intake manifold gasket to allow coolant to pass through on the cylinder head side.
12. Install the gasket on the cylinder head. The side labeled THIS SIDE UP must be facing up (see photo).
13. On a 7.4 liter V8 engine, install the front and rear seals into the cylinder block (see photo). Usually, the seals are provided with either rubber cuffs that are inserted into the holes in the block, or rubber mounting flags. Apply a bead of RTV sealant about 4mm in diameter on each corner of the seals where they meet the gasket.
Attention! On 7.4 liter models since 1996, the lower intake manifold gasket and reusable seals. They change only when damage is detected on them.
14. On V6, 5.0 and 5.7 liter engines, apply a 4mm bead of RTV sealant to the front and rear edges of the cylinder block (see photo). Apply a 12 mm bead to each cylinder head and place gaskets on them.
15. Carefully install the manifold in place, being careful not to disturb the gasket. Once the collector is in place, it must not be moved.
16. Lubricate bolt threads with Loctite 242 or equivalent, tighten bolts. While the sealant has not yet set, tighten the bolts to the specified torque, starting from the center, in a cross pattern (see photo). Tighten the bolts in 3 steps.
Other installation steps
17. Further assembly is carried out in the reverse order.
Upper intake manifold (models since 1996)
Attention! On all SFI models since 1996, a two-piece intake manifold has been installed. On all engines except 7.4 liters, the space between these two manifolds houses the units of the fuel injection system. On a 7.4 liter engine, the upper manifold must be removed before removing the lower manifold.
18. Disconnect the battery from the ground, drain the liquid from the cooling system.
19. Remove the air filter and an air duct.
20. Label and disconnect any wires that may interfere with the removal of the manifold section.
21. Remove throttle and cruise control cables along with brackets (see Chapter 4).
22. On V6 and V8 5.0 and 5.7 liter engines, disconnect the fuel lines leading from the manifold to the rear of the cylinder block.
23. Remove the ignition coil and bracket.
24. On a 7.4 liter V8 engine, disconnect the crankcase ventilation hose, EGR inlet, canister purge solenoid with connectors, disconnect any spark plug wires that may interfere with removal of the manifold section.
25. Remove the upper intake manifold. Mark the location of the studs and mounting bolts.
26. Install gasket and top manifold.
27. Tighten the bolts in two steps, starting from the center in a cross pattern. On a 7.4 liter engine, lubricate the bolt threads with a fixing compound.
28. Next, the assembly is performed in the reverse order.