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1. Disconnect the negative cable from the battery. 2. Drain the cooling system (refer Cooling System for the proper procedures). 3. Remove the generator. 4. Remove the air cleaner. 5. Perform the Fuel System Pressure release procedure (refer to Fuel Delivery and Air Induction System). Disconnect the fuel lines. 6. Disconnect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. Turn the intake manifold upside down. Support the manifold. Remove the bolts and lift the pan off the manifold. Discard the gasket. Turn the intake manifold upside down. Support the manifold. 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. Hand start all bolts. Tighten the bolts, in sequence as follows: Step 1 - Tighten bolts to 2.7 Nm (24 in. lbs.) torque. Step 2 - Tighten bolts to 5.4 Nm (48 in. lbs.) torque. Step 3 - Tighten bolts to 9.5 Nm (84 in. lbs.) torque. Step 4 - Check that all bolts are tightened to 9.5 Nm (84 in. lbs.) torque. Apply Mopar 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 gasket. The sealant should be slightly. 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. The words MANIFOLD SIDE should be visible on the center of each flange gasket. Step 1 - Tighten bolts 1 through 4, in sequence, to 8 Nm (72 in. lbs.) torque. Tighten in alternating steps 1.4 Nm (12 in. lbs.) torque at a time. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
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