How to Replace the Intake Manifold in a Dodge Intrepidby Contributor; Updated November 07, 2017
How to Replace the Intake Manifold in a Dodge Intrepid. Dodge offered the Intrepid from 1993 through 2004, when it was retired. During its years on the market, it was a bestseller, owing to its fearless or "intrepid" body design and sculpted look. It was a sleek standout among stodgy full-size sedans. The 3.5L V6 was a popular option the Intrepid ES, which is in demand today in the used vehicle market. The following steps guide you through the removal and the installation of the intake manifold on that engine.
Remove the Intake Manifold
Remove the engine cover from the top of the intake manifold. Take the accelerator and the speed control cable from the throttle level.
Remove the Idle Air Control (IAC) motor, the Intake Air Temperature (IAT) sensor and then remove the ground screw from the intake manifold. Locate the electrical connector and remove it from the Throttle Position (TO) sensor.
Label and disconnect the vacuum hoses from the tuning valve. Disconnect the PCV make-up air hose, the IAC motor supply hose and the purge hose from the throttle bodies.
Disconnect the brake booster hose, the PCV hose and any other vacuum hoses that can interfere with the removal of the manifold.
Loosen and remove the EGR tube-to-intake manifold plenum bolts and the bolts on each side of the plenum support bracket. Remove the intake manifold plenum and set it aside.
Pull the upper radiator hose from the thermostat housing, the heater hose from the back of the intake manifold. Loosen and remove the intake manifold bolts. Lift out the manifold.
Scrape the gasket material from the mating surfaces. Clean the surfaces with solvent and inspect them carefully for damage.
Install the Intake Manifold
Install the new intake manifold gasket and then set the lower manifold over it. Torque the bolts in sequence, working out from the center, to 21 foot pounds. Connect the upper radiator hose to the thermostat housing and attach the heater hose to the rear of the intake manifold.
Fit the intake manifold plenum over the new gasket. Make sure the ignition cables are out of the way. Torque the bolts to 21 foot pounds, working out from the center.
Replace the support bracket bolts. Connect the MAP sensor, the TP sensor, the IAC motor and the IAT sensor. Hook up the vacuum hose to the manifold tuning valve.
Put the EGR tub in place. Torque the manifold plenum screws to 17 ft. lbs. Be sure to align the EGR tube so that it makes contact with the insulation in the vacuum harness at the rear of the engine.
Connect the PCV valve hose. Connect the air cleaner plenum and the plenum hose as well as the ground wire. Reconnect the brake booster hose to the intake manifold plenum fitting.
Put the throttle body purge tubes, the intake manifold plenum cover and the negative battery cable in place. Fill the cooling system and then change the engine oil and oil filter.
Start the engine. Check for fuel and coolant leaks. Verify proper engine operation.
Before starting, relieve the pressure in the fuel system and then drain the cooling system. Disconnect the negative battery cable.
Drain the coolant into a sealable container or dispose of the coolant.