Dodge Dakota Sport 2001 Service Manual page 1088

AN
INTAKE MANIFOLD (Continued)
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the
water pump to turn in the opposite direction result-
ing in engine overheating. Refer to Group 7, Cool-
ing System for the proper procedure.
(14) Connect the air inlet hose and resonator to
the throttle body and the air cleaner. Tighten clamps
to 4 N·m (35 in. lbs.).
(15) Connect the battery negative cable.
(16) Start the engine and check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is constructed of cast iron
and has a ball flange designed exhaust pipe mount-
ing flange.
The exhaust manifold and the intake manifold
share a common one piece sealing gasket.
OPERATION
The exhaust manifold collects the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipe attached to the
manifold.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Raise the vehicle.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Lower the vehicle.
(6) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(7) Remove fasteners 2 through 5 and remove the
intake manifold (Fig. 78).
(8) Remove fasteners 1, 6 and 7 and remove the
engine exhaust manifold (Fig. 78).
CLEANING
Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks, Inspect mating sur-
faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.
Fig. 78 Intake/Exhaust Manifold Removal/Installation
INSTALLATION
(1) Clean the intake and engine exhaust manifolds
and cylinder head mating surfaces. DO NOT allow
foreign material to enter either the intake man-
ifold or the ports in the cylinder head.
(2) Install a new intake manifold gasket over the
alignment dowels on the cylinder head.
(3) Install the engine exhaust manifold assembly.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 78).
(4) Tighten bolt No.1 to 41 N·m (30 ft. lbs.) torque
(Fig. 78).
(5) Install the intake manifold on the cylinder
head dowels (Fig. 78).
(6) Install bolts 2 through 5 (Fig. 78). Tighten
these bolts to 31 N·m (23 ft. lbs.) torque.
(7) Install new engine exhaust manifold spacers
over the engine exhaust manifold mounting studs in
the cylinder head (Fig. 78).
(8) Tighten nuts 6 and 7 to 23 N·m (17 ft. lbs.)
torque (Fig. 78).
(9) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
INSTALLATION).
(10) Raise the vehicle.
(11) Connect the exhaust pipe to the engine
exhaust manifold. Tighten the bolts to 31 N·m (23 ft.
lbs.) torque.
(12) Lower the vehicle.
(13) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the battery negative cable.
(15) Start the engine and check for leaks.
ENGINE 2.5L 9 - 59
MANIFOLD -