Dodge Dakota Sport 2001 Service Manual page 1146

AN
INTAKE MANIFOLD (Continued)
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If the plenum pan was removed, position a new
gasket and install the plenum pan (Fig. 76). Tighten
bolts in the following sequence:
• Step 1. Tighten bolts to 5.4 N·m (48 in. lbs.)
• Step 2. Tighten bolts to 9.5 N·m (84 in. lbs.)
• Step 3. Check bolts to 9.5 N·m (84 in. lbs.)
(2) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 78). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(3) Apply Mopar GEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
Fig. 76 Plenum Pan Bolt Tightening Sequence
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter.
(4) Install the front and rear cross-over gaskets
(Fig. 77).
Fig. 77 Cross-Over Gaskets
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
ENGINE 3.9L 9 - 117