How to Replace the Intake Manifold in a Dodge Durangoby Contributor; Updated November 07, 2017
How to Replace the Intake Manifold in a Dodge Durango. Dodge designed the Durango about a half-size larger than a mid-size sport utility vehicle, thus creating its own niche between the mid-size and full-size SUV. The Durango featured a powerful 4.7L V8 for the 2001 to 2003 production years. The following steps guide you through the removal and installation of the intake manifold for the Durango with that engine.
Remove the Intake Manifold
Relieve the pressure in the fuel system, taking care to avoid fuel spillage. Disconnect the negative battery terminal. Remove the air intake duct from the throttle body.
Label all vacuum hoses, electrical wires and ground straps hoses and their connecting points on the intake manifold, then remove them. Pull the oil dipstick, the hood-to-cowl seal and the right engine lifting stud.
Take the throttle cable and the cruise control cable from the throttle body and the bracket. Disconnect and remove the accessory drivebelt. Take out the alternator and ignition coils.
Loosen and remove the bolts for the air conditioning compressor and set it aside without disconnecting the refrigerant lines. Take out the fuel rails and injectors, then remove the throttle body.
Drain about half the coolant from the cooling system (see Warnings). Remove the coolant temperature sensor to allow clearance for when the intake manifold is removed. Disconnect the heater hoses.
Loosen the manifold bolts and nuts in quarter-turn increments until they are loose enough to be remove by hand in the reverse order in which they are tightened.
Label and disconnect any remaining hoses that are in the way. Lift the manifold from the engine.
Install the Intake Manifold
Clean the intake manifold-to-cylinder head and mating surfaces. Check the gaskets on the manifold for damage and replace them as needed.
Set the manifold on the engine with the gaskets in proper alignment over the heads. Finger-tighten the manifold bolts. Tighten the bolts in sequence, working out from the center in a criss-cross pattern. Torque in three passes to 72 inch pounds.
Replace all components in the reverse order of the removal. Reconnect all hoses, wiring and lines.
Fill the cooling system with the appropriate amount and type of coolant. Start the engine and check for fuel, coolant or vacuum leaks.
Drain the coolant into a container that can be sealed. Dogs and cats will drink coolant left in open containers or on the floor. Ingestion is usually fatal.