Dodge Dakota (R1). Manual — part 519
exhaust gases to the exhaust pipes attached to the
manifolds.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Raise the vehicle.
(3) Remove the exhaust pipe to manifold nuts.
(4) Lower the vehicle.
(5) Remove three nuts, heat shield and washers
from the right side exhaust manifold, if necessary
(Fig. 71).
(6) Remove two nuts, heat shield and washers
from the left side exhaust manifold, if necessary (Fig.
72).
(7) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(8) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the exhaust manifold, install new studs.
(1) Position the exhaust manifolds on the two
studs located on the cylinder head. Install conical
washers and nuts on these studs (Fig. 73).
(2) Install new bolt and washer assemblies in the
remaining holes (Fig. 73). Start at the center arm
and work outward. Tighten the bolts and nuts to 24
N·m (18 ft. lbs.) torque.
(3) Position three washers, heat shield and nuts on
the right side exhaust manifold. Tighten nuts to 24
N·m (18 ft. lbs.).
(4) Position two washers, heat shield and nuts on
the left side exhaust manifold. Tighten nuts to 24
N·m (18 ft. lbs.).
Fig. 71 Exhaust Manifold Heat Shield—Right Side
1 - WASHER
2 - NUT AND WASHER
3 - EXHAUST MANIFOLD HEAT SHIELD
Fig. 72 Exhaust Manifold Heat Shield—Left Side
1 - WASHER
2 - NUT AND WASHER
3 - EXHAUST MANIFOLD HEAT SHIELD
Fig. 73 Exhaust Manifold Installation—5.9L Engine
1 - EXHAUST MANIFOLD (LEFT)
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
4 - EXHAUST MANIFOLD (RIGHT)
5 - BOLTS & WASHERS
9 - 264
ENGINE 5.9L
AN
EXHAUST MANIFOLD (Continued)
(5) Raise the vehicle.
(6) Assemble the exhaust pipe to the exhaust man-
ifold and secure with bolts, nuts and washers.
Tighten these nuts to 27 N·m (20 ft. lbs.) torque.
(7) Lower the vehicle.
(8) Connect the battery negative cable.
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 74) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme care
must be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
DIAGNOSIS AND TESTING—INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs occurs, the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 75). Dis-
card the gasket.
Fig. 74 Intake Manifold and Throttle Body—V-8 Gas
Engines Typical
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
AN
ENGINE 5.9L
9 - 265
EXHAUST MANIFOLD (Continued)
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 76).
(2) Tighten plenum pan mounting bolts as follows:
• Step 1. Tighten bolts to 5.4 N·m (48 in. lbs.)
• Step 2. Tighten bolts to 9.5 N·m (84 in. lbs.)
• Step 3. Check all bolts are at 9.5 N·m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver-
tical 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
(Fig. 78). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply Mopar
t GEN II Silicone Rubber Adhesive
Sealant, or equivalent, to the four corner joints. An
excessive 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 gas-
ket. The sealant should be approximately 5 mm (0.2
in) in diameter and 15mm (0.6in) long.
(5) Install the front and rear end seals (Fig. 77).
Make sure the molded dowel pins on the end seals
fully enter the corresponding holes in the cylinder
block.
(6) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
(7) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N·m
(200 in. lbs.) torque.
(8) Install the intake manifold bolts and tighten as
follows (Fig. 79):
• Step 1. Tighten bolts 1 through 4 to 8 N·m (72
in. lbs.) Tighten in alternating steps 1.4 N·m (12 in.
lbs.) at a time
• Step 2. Tighten bolts 5 through 12 to 8 N·m (72
in. lbs.)
• Step 3. Check all bolts are torqued to 8 N·m (72
in. lbs.)
• Step 4. Tighten all bolts in sequence to 16 N·m
(12 ft. lbs.)
• Step 5. Check all bolts are torqued to 16 N·m
(12 ft. lbs.)
(9) Install closed crankcase ventilation and evapo-
ration control systems.
Fig. 75 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
Fig. 76 Plenum Pan Bolt Tightening Sequence
9 - 266
ENGINE 5.9L
AN
INTAKE MANIFOLD (Continued)
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage (Refer to 14 -
FUEL
SYSTEM/FUEL
INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION) and if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL
DELIVERY/QUICK
CONNECT
FIT-
TING - STANDARD PROCEDURE).
(17) Install the accessory drive bracket and A/C
compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C
COMPRESSOR
-
INSTALLATION).
(18) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N·m (30 ft. lbs.) torque.
(19) Install the air cleaner.
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
Fig. 77 Front and End Rear Seals
1 - FRONT END SEAL
2 - REAR END SEAL
Fig. 78 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
Fig. 79 Intake Manifold Bolt Tightening Sequence
AN
ENGINE 5.9L
9 - 267
INTAKE MANIFOLD (Continued)
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