Intake Manifold

Complete removal and replacement of the intake manifold on a 2005 Dodge Viper 8.3L V10, including fuel rail removal, throttle body disconnection, and all associated sensors and hoses.

Warnings

Tools required

Parts

• Intake manifold gaskets (set of 10) × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• Fuel injector O-rings (set of 10) × 1 — Use OEM specification
• PCV valve grommet × 1 — Use OEM specification

Fluids

• Zerex G-05 HOAT 50/50 coolant — 2 qt

Preparation

1. Ensure engine is completely cold before beginning work
2. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
3. Remove engine cover by pulling upward on the four retention points
4. Place drain pan under vehicle to catch any coolant spillage
5. Have replacement gaskets and O-rings on hand before starting disassembly

Procedure

1. 1

   Relieve Fuel System Pressure
   Relieve fuel pressure per the factory procedure (remove the fuel pump relay from the PDC or use the fuel pump control relay as identified in the service manual for the 2005 Viper). Attempt to start the engine and allow it to run until it stalls. Crank the engine for an additional 5 seconds to ensure all residual pressure is relieved. Reinstall the fuel pump relay. Attach a fuel pressure gauge to the test port on the fuel rail and verify pressure is below 5 psi before proceeding.
2. 2

   Drain Coolant from Engine Block
   If the intake manifold has coolant passages/crossover on this engine, drain a small amount of coolant from the engine block drain (verify petcock location in the service manual) into a drain pan to prevent spillage. Confirm in the factory manual whether the 2005 Viper 8.3L intake manifold carries coolant before draining. This prevents coolant spillage when removing intake manifold components. Close the petcock when draining is complete.
3. 3

   Remove Air Intake System
   Disconnect the air intake tube from the throttle body by loosening the hose clamp. Remove the entire air box assembly by releasing the mounting clips and disconnecting any intake air temperature sensor connector if present. Remove the assembly from the engine bay to provide access to the intake manifold.
4. 4

   Disconnect Throttle Body and Cables
   Disconnect the electrical connector(s) at the throttle body (throttle position sensor / electronic throttle control, and idle air control valve if equipped) as identified for this vehicle. If the vehicle uses a mechanical throttle cable, disconnect the throttle cable by sliding the cable end out of the throttle lever, then remove the cable bracket bolts; disconnect the cruise control cable if equipped. If the vehicle uses electronic throttle control, disconnect the ETC connector instead — verify configuration in the service manual. Label all connections for reassembly.
5. 5

   Remove Throttle Body
   Remove the four throttle body mounting bolts securing the throttle body to the intake manifold. Carefully pull the throttle body away from the manifold and set aside. Inspect the gasket and replace if damaged. Plug the intake manifold opening with a clean shop towel to prevent debris entry.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
6. 6

   Disconnect Fuel Rails and Injectors
   Disconnect the fuel supply line from the fuel rail using the appropriate fuel line disconnect tool. Cap the fuel line immediately with a plastic plug to prevent contamination. Disconnect all 10 fuel injector electrical connectors and label them for correct reassembly. If equipped with a vacuum-referenced fuel pressure regulator on the rail, disconnect its vacuum hose from the intake manifold. Note: returnless systems regulate pressure at the pump module and have no rail-mounted vacuum regulator — verify system type.
7. 7

   Remove Fuel Rails
   Remove the four fuel rail mounting bolts (two per rail, one at each end). Carefully lift both fuel rails with injectors still attached straight up and out of the intake manifold. Place the fuel rail assemblies on a clean work surface. If injectors remain in the manifold, carefully extract them and keep with their respective fuel rail.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
8. 8

   Disconnect Intake Manifold Sensors and Hoses
   Disconnect the manifold absolute pressure (MAP) sensor electrical connector. Disconnect the PCV valve and hose from the rear of the intake manifold. Disconnect all vacuum hoses connected to the intake manifold, including brake booster hose, EVAP purge solenoid hose, and any other vacuum lines. Label each connection. Disconnect the coolant bypass hoses from the intake manifold crossover if present.
9. 9

   Remove Intake Manifold Mounting Bolts
   Working from the outside bolts toward the center, remove all intake manifold mounting bolts (verify exact count in the service manual) in the reverse order of the tightening sequence. Keep track of bolt locations as some may be different lengths. Once all bolts are removed, check for any remaining hoses or wiring that may still be attached.
10. 10

    Remove Intake Manifold
    Carefully lift the intake manifold assembly straight up and off the cylinder heads. The manifold may be adhered to the gaskets and require gentle rocking to break the seal. Do not pry between the manifold and heads as this can damage sealing surfaces. Once free, remove the manifold from the engine bay and place on a protected work surface.
11. 11

    Clean Sealing Surfaces
    Remove all old gasket material from both the cylinder head surfaces and the intake manifold mating surfaces using a non-metallic gasket scraper. Be extremely careful not to gouge or scratch the aluminum surfaces. Clean all surfaces thoroughly with brake cleaner and lint-free shop towels. Inspect for any cracks, warping, or damage. Ensure all bolt holes are clean and free of debris or old thread sealant.
12. 12

    Install New Gaskets and Position Manifold
    Place new intake manifold gaskets on each of the 10 cylinder head intake ports. Ensure gaskets are properly aligned with the port openings and bolt holes. The gaskets should stay in place without adhesive. Carefully lower the intake manifold into position, aligning all ports and bolt holes. Ensure no gaskets have shifted during installation.
13. 13

    Install and Torque Intake Manifold Bolts
    Hand-thread all intake manifold bolts to prevent cross-threading. Following the factory tightening sequence, torque all bolts to the manufacturer-specified value in the staged sequence given in the service manual. Verify both bolt count and torque spec against the 2005 Viper factory service manual before proceeding. Verify the tightening sequence in the service manual before proceeding.
    Torque spec

    Intake Manifold Bolt25 Nm (18 lb-ft)
14. 14

    Reinstall Fuel Rails and Injectors
    Install new O-rings on all fuel injectors, lubricating them lightly with clean engine oil. Press the injectors into the fuel rails if they were removed. Carefully align the fuel rail assemblies with the intake manifold injector bores and press down firmly until all injectors are fully seated. Install the fuel rail mounting bolts and torque to the value specified in the service manual, following the specified sequence. Verify bolt count and torque spec against the 2005 Viper factory service manual.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
15. 15

    Reconnect Fuel System and Sensors
    Reconnect all 10 fuel injector electrical connectors in their original positions. Remove the cap from the fuel supply line and reconnect it to the fuel rail, ensuring it clicks firmly into place. Reconnect the fuel pressure regulator vacuum hose. Reconnect the MAP sensor electrical connector. Reconnect the PCV valve and hose to the intake manifold using the new grommet if necessary.
    Torque spec

    PCV Valve8 Nm (6 lb-ft)
16. 16

    Reinstall Throttle Body
    Install a new throttle body gasket on the intake manifold. Position the throttle body onto the manifold and install the four mounting bolts. Torque the throttle body bolts to the value specified in the service manual following the specified crossing pattern. Verify the throttle body bolt torque spec against the 2005 Viper factory service manual. Reconnect the TPS and IAC valve electrical connectors.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)
17. 17

    Reconnect All Remaining Components
    Reinstall the throttle cable and bracket, adjusting cable free play to specification. Reconnect the cruise control cable if equipped. Reconnect all vacuum hoses to their original positions using the labels applied during removal. Reconnect any coolant bypass hoses to the intake manifold. Double-check that all electrical connectors and hoses are properly seated.
18. 18

    Reinstall Air Intake System
    Reinstall the air box assembly and secure the mounting clips. Reconnect the mass airflow sensor electrical connector. Connect the air intake tube to the throttle body and tighten the hose clamp securely. Ensure all air intake components are properly sealed to prevent unmetered air from entering the system.
19. 19

    Refill Coolant and Check for Leaks
    If coolant was drained, refill the cooling system with the OEM-specified HOAT coolant (50/50) to the correct level. Verify coolant type and required quantity against the 2005 Viper service manual; if the intake carries no coolant, no refill is needed. Reconnect the negative battery cable. Turn the ignition to the ON position (do not start) and cycle it 3-4 times to prime the fuel system. Check all fuel connections for leaks. Start the engine and allow it to reach operating temperature while monitoring for fuel, coolant, or vacuum leaks.

Reassembly

1. Torque all fasteners to specification using a calibrated torque wrench
2. Follow factory tightening sequences for intake manifold bolts, fuel rail bolts, and throttle body bolts
3. Replace all gaskets and fuel injector O-rings during reassembly
4. Ensure all electrical connectors are fully seated and locked
5. Verify all vacuum hoses are connected to their original locations

Verification

• With engine running, check for fuel leaks at all fuel rail connections and injectors
• Check for coolant leaks at intake manifold coolant passages
• Check for vacuum leaks by listening for hissing sounds around the intake manifold and throttle body
• Verify engine idles smoothly with no rough running or misfires
• Scan for diagnostic trouble codes using an OBD-II scanner; address any fuel system or sensor codes
• Road test the vehicle and verify normal throttle response and power delivery
• Recheck coolant level after engine has cooled and top off if necessary

Related trouble codes on this vehicle

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