Dodge Dakota Sport 2001 Service Manual page 1087

9 - 58 ENGINE 2.5L
INTAKE MANIFOLD (Continued)
• The manifold air temperature sensor at the
intake manifold.
• The fuel injectors.
• The oxygen sensor.
(10) Disconnect the crankcase ventilation (CCV)
vacuum hose and manifold absolute pressure (MAP)
sensor vacuum hose connector at the intake mani-
fold.
(11) Disconnect vacuum hose from vacuum port on
the intake manifold.
(12) Disconnect CCV hose at the cylinder head
cover (Fig. 77).
Fig. 77 Crankcase Ventilation (CCV) Hose—2.5L
1 - AIR INLET FITTING
2 - AIR FILTER COVER
3 - FIXED ORIFICE FITTING
(13) Remove the molded vacuum harness.
(14) Disconnect the vacuum brake booster hose at
the intake manifold.
(15) Remove bolts 2 through 5 securing the intake
manifold to the cylinder head (Fig. 78). Slightly
loosen bolt No.1 and nuts 6 and 7.
(16) Remove the intake manifold and gaskets.
Drain the coolant from the manifold.
CLEANING
CAUTION: DO NOT allow foreign material to enter
either the intake manifold ports, or the cylinder
head ports.
Clean the intake manifold to cylinder head mating
surfaces.
INSPECTION
Inspect manifold to cylinder head mating surfaces
for cracks and/or pitting. Inspect manifold for warp
or twist.
INSTALLATION
(1) Clean the intake manifold and cylinder head
mating surfaces. DO NOT allow foreign material
to enter either the intake manifold or the ports
in the cylinder head.
(2) Install the new intake manifold gasket over the
locating dowels.
(3) Position the manifold in place and finger
tighten the mounting bolts.
(4) Tighten the fasteners in sequence and to the
specified torque (Fig. 78).
• Fastener No.1—Tighten to 41 N·m (30 ft. lbs.)
torque.
• Fasteners Nos.2 through 5—Tighten to 31 N·m
(23 ft. lbs.) torque.
• Fasteners Nos.6 and 7—Tighten to 23 N·m (17
ft. lbs.) torque.
(5) Connect fuel supply tube to the fuel rail inlet
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(6) Pull out on the fuel supply tube to ensure that
it is locked in place.
(7) Connect the molded vacuum hoses to the vac-
uum port on the intake manifold and the cylinder
head cover.
(8) Connect the electrical connectors.
• The throttle position sensor.
• The idle air control motor.
• The coolant temperature sensor at the thermo-
stat housing.
• The fuel injectors.
• The air manifold temperature sensor.
• The oxygen sensor.
(9) Connect the CCV vacuum hose and MAP sen-
sor vacuum hose connectors to the throttle body.
(10) Install the power steering pump and bracket
assembly to the water pump and intake manifold.
Hand start the three (3) tensioner bracket to p/s
pump to intake manifold bolts and the two (2) ten-
sioner bracket to water pump bolts.
(11) Tighten the power steering pump bolts to 28
N·m (21 ft. lbs.) Tighten the tensioner bracket to
water pump bolts to 28 N·m (21 ft. lbs.).
(12) Connect the accelerator cable, cruise control
cable (if equipped), and the transmission line pres-
sure cable (if equipped) to the hold-down bracket and
the throttle lever.
(13) Install and tension the accessory drive belt.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION).
AN