Intake Manifold Vacuum Port Repair

The composite intake manifold vacuum ports can be repaired. Although, if the manifold plenum chamber is damaged or cracked, the manifold must be replaced.
To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following procedure:





NOTE: While performing this procedure, avoid getting the manifold material residue into the plenum chamber.

1. File or sand the remaining port back until a flat surface is obtained (plane normal to nipple (port) axis).





Fig. 38

2. Drill out the nipple (port) base using a 7/16" drill bit (Fig. 38).
3. Using a 1/4"-18 NPT pipe tap, cut internal threads (Fig. 38). Use caution to start tap in a axis same as original nipple.
4. Apply Mopar Thread Sealant to threads of repair nipple(s).
5. Install repair nipple(s). Do not over torque repair nipple(s).