1994 Dodge Ram 1500 Q&A
1994 Dodge Ram 1500 Question: intake manifold
Sounds like you need to recheck your work, possible gasket not sealing causing vacuum leak or you rehooked up components on top the wrong way or incomplete connections. Always recheck what you just did if you have new probs after this type of work. - raiderron
The most common problem when replacing the intake gasket is the gasket shifts out of place or the narrow strip of gasket material between the two adjacent intake ports either tears or distorts when installing and torquing the manifold bolts. 1.Install the plenum pan, if removed, as follows: a.Turn the intake manifold upside down. Support 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 Plenum Pan Bolt Tightening Sequence , 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 tightened to 9.5 N·m (84 in. lbs.) torque. 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. 4.Apply a bead of Mopar Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. The sealant bead height should be slightly higher than the cross-over gaskets, approximately 5 mm (0.2 in) An excessive amount of sealant is not required to ensure a leak proof seal, and an excessive amount of sealant may reduce the effectiveness of the flange gasket. 5.Install the front and rear cross-over gaskets onto the dowels Cross-Over Gaskets and Locator Dowels 6.Install the flange gaskets. Ensure that the vertical 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 Intake Manifold Flange Gasket Alignment The words MANIFOLD SIDE should be visible on the center of each flange gasket. 7.Carefully lower intake manifold into position on the cylinder block and cylinder heads. long studs at the front and rear of the manifold will help to align the intake manifold. After intake manifold is in place, inspect to make sure seals are in place. Remove alignment studs if used. The manifold must be torqued in sequence starting from the center bolt on one bank and alternating from one bank to the next, moving outwards from the center. 5.2L / 5.9L Intake Manifold Flange Bolt Torque Procedure •Step 1 - Tighten bolts 1 thru 4, in sequence, to (72 in. lbs.) torque. Tighten in alternating steps 12 in. lbs.) torque at a time. •Step 2 - Tighten bolts 5 thru 12, in sequence, to (72 in. lbs.) torque. •Step 3 - Check that all bolts are tightened to 8 N·m (72 in. lbs.) torque. •Step 4 - Tighten all bolts, in sequence, to 16 N·m (12 ft. lbs.) torque. •Step 5 - Check that all bolts are tightened to 16 N·m (12 ft. lbs.) torque. BTW, If by chance you removed the distributor for any reason, the distributor will have to be re-synced with the Crank Position Sensor. The Distributor contains the Camshaft Position Sensor and does not effect engine timing.The degree scale on the SET SYNC screen of the DRB is referring to fuel synchronization only. To verify correct distributor rotational position, connect the DRB scan tool (see your dealership) to the data link connector. - Johnny Mopar
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