Dodge ram truck 3500 1996 Service Manual page 1209

BR EXHAUST SYSTEM AND INTAKE MANIFOLD 1 1 - 7
REMOVAL AND INSTALLATION (Continued)
INTAKE MANIFOLD—V-6 and V-8 ENGINES
R E M O V A L
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
(3) Remove the generator.
(4) Remove the air cleaner.
(5) Perform the Fuel System Pressure release pro­
cedure (refer to Group 14, Fuel System). Disconnect
the fuel lines.
(6) Disconnect the accelerator linkage and i f so
equipped, the speed control and transmission kick-
down cables.
(7) Remove the return spring.
(8) Remove the distributor cap and wires.
(9) Disconnect the coil wires.
(10) Disconnect the heat indicator sending unit
wire.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems.
(13) Remove intake manifold bolts.
(14) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(15) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(16) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 10). Dis­
card the gasket.
FUEL RAIL
MOUNTING BOLTS
FUEL RAIL
CONNECTING
HOSES
J9409-134
Fig. 10 Throttle Body Assembly
(17) Remove the plenum pan as follows:
(a) Turn the intake manifold upside down. Sup­
port the manifold.
(b) Remove the bolts and lift the pan off the
manifold. Discard the gasket.
INSTALLATION
(1) Install the plenum pan, i f removed, as follows:
(a) Turn the intake manifold upside down. Sup­
port the manifold.
(b) Place a new plenum pan gasket onto the seal
rail of the intake manifold. Position the pan over
the gasket. Align all the gasket and pan holes with
the intake manifold.
(c) Hand start all bolts.
(d) Tighten the bolts, in sequence (Fig. 11), as
follows:
• Step 1—Tighten bolts to 2.7 N-m (24 in. lbs.)
torque.
• Step 2—Tighten bolts to 5.4 N-m (48 in. lbs.)
torque.
• Step 3—Tighten bolts to 9.5 N-m (84 in. lbs.)
torque.
• Step 4—Check that all bolts are tighten to 9.5
N-m (84 in. lbs.) torque.
V-6 V-8
J 9 3 1 1 - 1 4
Fig. 11 Plenum Pan Bolt Tightening Sequence
(2) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N-m
(200 in. lbs.) torque.
(3) Place the 4 plastic locator dowels into the holes
in the block (Fig. 12).
(4) Apply Mopar® Silicone Rubber Adhesive Seal­
ant, or equivalent, to the four corner joints. An exces­
sive amount of sealant is not required to ensure a
leak proof seal. However, an excessive amount of
sealant may reduce the effectiveness of the flange
gasket. The sealant should be slightly higher than
the cross-over gaskets, approximately 5 mm (0.2 in).
(5) Install the front and rear cross-over gaskets
onto the dowels (Fig. 12).
(6) Install the flange gaskets. Ensure that the ver­
tical port alignment tab is resting on the deck face of