Intake manifold remove @ replace - 2002 Dodge Dakota Club Cab

Please watch the video.

98 Grand Cherokee 5 2 V8 318 MOPAR M1 Intake Manifold

Well basically, you remove the intake plenum and replace the gasket and reinstall the plenum. Here are the steps:

1. Disconnect the negative battery cable from the remote jumper terminal located at the right strut tower.
2. Remove the air inlet resonator and tube.
3. Remove the throttle actuator cables from the throttle arm and bracket.
4. Disconnect Secondary Runner Valve (SRV), Manifold Tuning Valve (MTV), Throttle Position Sensor (TPS), Idle Air Control (IAC) motor electrical connectors.
5. Remove the electrical connector and the Intake Air Temperature/Manifold Absolute Pressure (TMAP) sensor.
6. Disconnect vacuum hoses from the Secondary Runner Valve (SRV) reservoir, Speed Control reservoir, and PCV.
7. Remove right and left intake manifold supports.
8. Remove support brackets at the intake manifold front corners and MTV.
9. Loosen upper fastener attaching throttle body to support bracket.
10. Remove clips attaching EGR tubes to intake manifold.
11. Remove intake manifold bolts and manifold
12. Remove old gaskets, Clean gasket surfaces, and install new gaskets.
13. Reverse steps to reinstall manifold

Remove the manifold and send it out to a machine shop, they can remove repair this broken bolt. Cost about $50.00

if im not mistaken the number 3 coil is on the right hand side of the motor so you will need to remove the intake manifold to gain access to it.
Intake Manifold Removal

1. Remove the engine cover (if equipped).
2. Remove the air filter outlet pipe.
3. Remove the positive crankcase ventilation hose.
4. Remove the air cleaner resonator.
5. Disconnect the throttle body electrical connectors.
6. Disconnect the electrical connectors.
   
7. Detach the vacuum hoses.
   • Press the retaining ring. (1)
   • Detach the vacuum hose. (2)
   
   
8. Disconnect the vacuum hose.
   
9. Detach the injector harness electrical connector from the intake manifold support bracket.
10. Remove the intake manifold support bracket.
    
11. Detach the engine wiring harness bracket.
    
12. Detach the intake manifold support bracket.
    
    NOTE: Remove and discard the O-ring seal.
    
13. Detach the throttle body.
    • Remove the retaining bolts.
14. Remove the intake manifold.
    • Remove and discard the intake manifold gaskets.

Hello,

Here is a detailed summary on the procedure of how to replace the intake manifold gasket on a 1996 gmc jimmy;
REMOVING THE UPPER INTAKE MANIFOLD(PLENUM)
STEP 1 Disconnect Battery (may not be absolutely necessary, but a good practice to avoid shorting a positive wire to ground).


STEP 2 Remove serpentine belt.

STEP 3 Drain the coolant.

STEP 4 Remove air cleaner ducting and disconnect wires.

STEP 5 Disconnect throttle linkage and bracket.

STEP 6 Disconnect cruise control cable.

STEP 7 Remove brake booster vacuum hose at manifold.

STEP 8 Remove PCV hose.

STEP 9 Remove ignition coil and bracket.

STEP 1O Remove purge solenoid and bracket.

STEP 11 Relieve fuel pressure at test port.

STEP 12 Remove fuel lines and bracket.

STEP 13 Remove upper intake manifold.

REMOVING THE LOWER INTAKE MANIFOLD
STEP 1 Remove the distributor and label the spark plug wires.

STEP 2 Remove heater hoses and bypass hose.

STEP 3 Remove upper radiator hose.


STEP 4 Remove EGR valve?

STEP 5 Remove sensors and bracket on right side.

STEP 6 Remove EGR tube, clamp and bolt.

STEP 7 Remove PCV valve (and replace).

STEP 8 Unbolt A/C compressor and move it aside.

STEP 9 Loosen compressor bracket and slide forward, but do not remove it.

STEP 10 Remove alternator bracket bolt (or remove alternator and set aside)

STEP 11 Unplug all vacuum lines from intake manifold.


STEP 12 Unplug all electrical connectors from manifold.

STEP 13 Take note of the intake manifold bolts and mark the location of the bolts.


STEP 14 Remove intake manifold bolts, and manifold.

STEP 15 Clean mating surfaces

THE MAIN INSTALLATION
STEP1 Set the new gaskets in place and apply silicone to flat areas on front and rear of engine block.

STEP2 Apply thread locking compound to manifold bolts.

STEP 3 Install the manifold and tighten bolts to 35 ft-lbs, in proper sequence.

STEP4 Install the distributor.

STEP5 Install the upper intake manifold.



The remaining installation procedures are basically the reverse of removal.


Have a nice day.

You didn't post the size of your engine so please pick the appropriate one:

3.8L

1. Relieve the fuel system pressure.
   
2. Drain the cooling system.
   

1. Remove or disconnect the following:
2. Negative battery cable
   

• Supercharger
  
• Thermostat housing
  
• Exhaust Gas Recirculation (EGR) tube at the intake manifold
  
• Engine Control Temperature (ECT) sensor
  
• Intake manifold
  

To install:

1. Install or connect the following:
   
   • Intake manifold with new gaskets. Torque the bolts, working from the center out, to 11 ft. lbs. (15 Nm).
     
   • ECT sensor connector
     
   • EGR tube to the intake manifold
     
   • Thermostat housing
     
   • Supercharger
     
   • Negative battery cable
     
2. Refill and bleed the cooling system.
   
3. Run the engine and check for leaks and proper engine operation.
   

4.6L
4.6L Engine

1. Remove the brake booster hose from the throttle body.
   
2. Remove the fuel pressure regulator vacuum tube from the fuel pressure regulator and the water crossover.
   
3. Remove the PCV fresh air feed tube from the camshaft cover and the throttle body.
   
4. Remove the PCV dirty air tube from the PCV orifice in the right camshaft cover and from the intake manifold.
   
5. Disconnect the fuel injector electrical connectors from the fuel injectors.
   
6. Remove the fuel injector wiring harness.
   
7. Remove the fuel rail bracket nut from the engine lift bracket.
   
8. Remove the fuel rail studs.
   
9. Lift and remove the fuel rail with injectors.
   
10. Loosen the plenum duct clamp in order to remove the intake manifold.
    
11. Remove the intake manifold bolts.
    
12. Remove the intake manifold.
    

To install:

1. Install the intake manifold, fitting the plenum duct over the intake manifold duct.
   
2. Loosely install the intake manifold bolts.
   

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Intake manifold torque sequence-4.6L engine

2. Tighten the intake manifold bolts in sequence. Tighten the intake manifold bolts to 89 inch lbs. (10 Nm).
   
4. Tighten the plenum duct clamp to the intake manifold. Tighten the plenum duct clamp to 24 inch lbs. (2.75 Nm).
   
5. Inspect the fuel injector O-rings. Ensure the fuel injector O-rings are not missing, misaligned or damaged. Replace the O-rings if necessary.
   
6. Lubricate the intake manifold fuel injector bores with light mineral oil (GM P/N 9981704), clean engine oil, or equivalent.
   
7. Install the fuel rail with fuel injectors as an assembly.
   
8. Install the fuel rail studs. Tighten the fuel rail studs to 80 inch lbs. (9 Nm).
   
9. Install the fuel rail bracket nut to the engine lift bracket. Tighten the fuel rail bracket nut to 89 inch lbs. (10 Nm).
   
10. Install the fuel injector wiring harness.
    
11. Connect the fuel injector electrical connectors to the fuel injectors.
    
12. Install the PCV dirty air tube to the PCV orifice in the right camshaft cover and to the intake manifold.
    
13. Install the PCV fresh air feed tube to the camshaft cover and the water crossover.
    
14. Install the fuel pressure regulator vacuum tube to the fuel pressure regulator and the throttle body.
    
15. Install the brake booster hose to the throttle body.
    

3.8L Engine (most common) Upper Intake Manifold To Remove:

1. Drain the cooling system.
2. Remove or disconnect the following:
   • Negative battery cable.
   • Fuel injector sight shield.
   • Air cleaner intake duct.
   • Right spark plug wires from the ignition control module and reposition.
3. Relieve the fuel pressure.
4. Remove or disconnect the following:
   • Fuel rail assembly.
   • Brake booster hose from the vacuum source manifold in the upper intake manifold.
   • Exhaust Gas Recirculation Valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield.
   • Throttle body support bracket upper bolt.
5. Disconnect the electrical connectors from the following:
   • EVAP purge solenoid
   • Throttle Position (T/P) sensor
   • Idle Air Control (IAC) valve
   • Manifold Absolute Pressure (MAP) sensor
   • Mass Air Flow (MAF) sensor
   • EVAP purge solenoid vacuum line from the throttle body.
   • Accelerator and the cruise control cables with the bracket from the throttle body.
6. Remove or disconnect the following:
   • Upper intake manifold bolts and stud.
   • Clean the upper intake manifold bolt threads.
7. Remove or disconnect the following:
   • Upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
   • Upper-to-lower intake manifold carrier gasket from the upper intake manifold.
8. If the upper intake manifold is being replaced, remove the following:
   • Throttle body assembly.
   • Manifold Absolute Pressure (MAP) sensor.
   • Positive Crankcase Ventilation (PCV) valve.
   • Vacuum source manifold.

Upper intake manifold bolt torque sequence (3.8L engine)

To Install:

1. If the manifold was replaced, install or connect the following:
   • Vacuum source manifold.
   • Positive Crankcase Ventilation (PCV) valve.
   • Manifold Absolute Pressure (MAP) sensor.
   • Throttle body assembly.
   • Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
2. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold. NOTE: Apply thread lock compound, to the bolt threads before assembly.
   
3. Install or connect the following:
   • Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
   • Accelerator and the cruise control cables with the bracket to the throttle body.
   • EVAP purge solenoid vacuum line to the throttle body.
4. Connect the electrical connectors to the following:
   • Mass Air Flow (MAF) sensor
   • Manifold Absolute Pressure (MAP) sensor
   • Idle Air Control (IAC) valve
   • Throttle Position (T/P) sensor
   • EVAP purge solenoid
5. Install or connect the following:
   • Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
   • EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
   • Brake booster hose to the vacuum source manifold.
   • Fuel rail assembly.
   • Right spark plug wires.
   • Air cleaner intake duct.
   • Fuel injector sight shield.
6. Connect the negative battery cable.
7. Fill the cooling system.
8. Inspect for fluid or vacuum leaks.

Lower Intake Manifold (W/O Supercharger) To Remove:

1. Remove or disconnect the following:
   • Upper intake manifold.
   • Generator brace.
   • Drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe.
   • Exhaust gas recirculation EGR outlet pipe bolt from the lower intake manifold.
   • Radiator inlet hose from the water outlet housing.
   • ECT sensor electrical connector.
   • Right upper engine mount strut bracket.
   • Generator brace bracket bolts.
   • Generator brace bracket.
   • Lower intake manifold bolts.
   • Lower intake manifold.
   • Lower intake manifold seals.
   • Lower intake manifold gaskets.
2. If replacing the lower intake manifold, Remove or disconnect:
   • Water outlet housing bolt and stud
   • Water outlet housing
   • Gasket and the thermostat.
   • ECT sensor.
3. Inspect the flatness of inlet flanges.
4. Clean the intake manifold mating surfaces.
5. Clean the intake manifold bolts and bolt holes of adhesive compound.

To Install:

1. If removed, install the ECT sensor.
   • Tighten the ECT sensor to 18 ft. lbs. (25 Nm)
2. If removed, install the thermostat, the gasket, and the water outlet housing.
3. If removed, install the water outlet housing bolt and the stud.
   • Tighten the bolt and stud to 20 ft. lbs. (27 Nm)
4. Install or connect the following:
   • Lower intake manifold gaskets. NOTE: Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
     
   • Lower intake manifold seals.
   • Lower intake manifold.
   • Lower intake manifold bolts.
   NOTE: Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.
   
5. Tighten the lower intake manifold bolts in sequence to 11 ft. lbs. (15 Nm)
   
   
6. Install or connect the following:
   • Generator brace bracket.
   • Generator brace bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
   • Right upper engine mount strut bracket.
   • ECT sensor electrical connector.
   • Radiator inlet hose to the water outlet housing.
   • EGR outlet pipe to the lower intake manifold.
   • EGR outlet pipe bolt to the lower intake manifold. Tighten the bolt to 21 ft. lbs. (29 Nm)
   • Drive belt tensioner.
   • Generator brace.
   • Upper intake manifold.
7. Inspect for leaks.

Lower Intake Manifold (W/ Supercharger) To Remove:

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the supercharger.
4. Remove the thermostat housing.
5. Remove the EGR pipe at the intake manifold.
6. Disconnect the electrical connection at the temperature sensor.
7. Remove the intake manifold and gaskets.

NOTE: The coolant bypass tube will release from the intake manifold when the manifold is removed.
To Install:

1. Clean the gasket sealing surfaces.
2. Install the intake manifold gaskets.
3. Align the coolant bypass tube with the opening in the intake manifold and install the manifold. Tighten the bolts to 11 lb ft (15 Nm).
4. Install the electrical connector to the temperature sensor.
5. Install the EGR pipe to the intake manifold.
6. Install the thermostat housing.
7. Install the supercharger.
8. Fill the cooling system.
9. Connect the negative battery cable.

its easy my friend, take your tools, drain engine oil and coolant, remove left side rocker ornament and air duct of intake manifold, collector,hose wires, harness etc, remove ignition coils, egr tube,intake manifold collector supports and the manifold( right cylinder head only,) remove intake manifold, and replace knock sensor to avoid some trouble in the future

3.8L Engine

NOTE The 3.8L (VIN K) non-supercharged engine uses a two-piece intake manifold consisting of an upper air plenum which mounts the throttle body and a lower intake manifold assembly which houses the fuel injectors. The 3.8L (VIN 1) supercharged engine uses a similar lower intake manifold. The supercharger serves as the upper manifold.
Lower Manifold

NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
The 3.8L (VIN 1) supercharged engine uses a manifold similar to the 3.8L (VIN K), but the supercharger serves as the upper manifold.

1. Disconnect the negative battery cable.
2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
3. Remove the upper intake manifold using the procedure above.
4. Remove the EGR outlet pipe from the intake manifold.
5. Detach the engine coolant temperature sensor wiring harness from the sensor.
6. Remove the lower intake manifold bolts and carefully lift off the manifold.

To install:


Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine

1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces and between the lower manifold and the cylinder heads..
2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Apply thread-locking compound to the bolt threads. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 11 ft. lbs. (15 Nm). Follow the toque sequence, starting in the center, then working outwards in a circle.
3. Install the remaining components in the reverse order of the removal process.

Upper Intake Manifold (Plenum)

1. Disconnect the negative battery cable.
2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
3. Tag for identification, then remove the right side spark plug wires.
4. Disconnect the ignition wires from the fuel rail.
5. Remove the fuel rail. Please see Section 5.
6. Remove the cable bracket from the intake manifold.
7. Remove the throttle body.

NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold.

1. Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engine.

Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine
To install:

1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 89 inch lbs. (10 Nm). Follow the torque sequence, starting in the center, then working outwards in a circle.
3. Install the remaining components in the reverse order of the removal process.