Dodge ram truck 3500 1996 Service Manual page 1212

11 - 1 0 EXHAUST SYSTEM AND INTAKE MANIFOLD
REHOWAL AND INSTALLATION (Continued)
UPPER INTAKE
MANIFOLD
THROTTLE
BODY (MPI)
LOWER
INTAKE
MANIFOLD
Fig. 18 Upper Intake Manifold and Throttle Body
J951M
Fig. 19 Lower Intake Manifold
INSTALLATION
(1) Install the intake manifold side gaskets. Be
sure that the locator dowels are positioned in the
head (Fig. 21).
(2) Peel off the protective paper (blue - rear and
brown - front) and press firmly onto the block (Fig.
20). BE SUEE THE BLOCK IS O I L FREE.. Align­
ing slots in end seals with notches in intake manifold
gaskets.
(3) Insert Mopar® Silicone Rubber Adhesive Seal­
ant, or equivalent, into the four corner pockets (Fig.
20). F i l l the pocket, b u t DO NOT overfill.
(4) The lower intake manifold MUST be installed
within 3 minutes of sealant application. Carefully
lower intake manifold into position on the cylinder
block and heads. After intake manifold is in place,
inspect to make sure seals and gaskets are in place.
Finger start all the lower intake bolts.
(5) Tighten the lower intake manifold bolts in
sequence to 54 N-m (40 ft. lbs.) torque (Fig. 19).
INTAKE MANIFOLD
GASKET
SEALANT
J9409-65
Fig. 20 Lower Intake Manifold Gaskets
.LOCATOR DOWELS-
INTAKE MANIFOLD GASKETS
LOCATOR DOWELS
J9409-64
Fig. 21 Intake Manifold Flange Gasket Alignment
(6) Using a new gasket, position the upper intake
manifold onto the lower intake manifold.
(7) Finger start all bolts, alternate one side to the
other.
(8) Tighten upper intake manifold bolts in
sequence to 22 N-m (16 ft. lbs.) torque (Fig. 18).
(9) Using a new gasket, install the throttle body
onto the upper intake manifold. Tighten the bolts to
23 N-m (200 in. lbs.) torque.
(10) Install closed crankcase ventilation and evap­
oration control systems.
(11) Connect the heater hoses and bypass hose.
(12) Connect the vacuum lines.
(13) Install the coil assemblies and the ignition
cables.
(14) Connect the accelerator linkage and i f so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel lines.