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  #1  
Old 11-24-2009, 05:51 AM
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2001 to 2003 intake manifold swap

I recently found a great deal on a 2003 intake manifold and matching TB. Just curious if anyone has gone through with this swap and if they ran into any problems or if they had any suggestions on what to look out for.
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  #2  
Old 11-24-2009, 06:23 AM
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I haven't done that exact swap but I've been much further into it with the supercharger/manifold. It really isn't to bad but just will take you a while your first time. I'd plan a good part of a day if your doing it for the first time but realistically it can be done much faster (the first time with anything always seems to take 3 times a long)

The thing that sucks the most is that you are probably going to have to pull the heater lines, this really isn't a big problem but you will end up getting coolant everywhere (and I personally don't like it, especially cause I always have to end up laying in it after spilling it all over the garage lol)

I would drain as much coolant from the radiator as possible but you will still end up having it spill when you pull the heater lines. Not a big deal, just be prepared for it with something to clean it up.

If you aren't afraid to get dirty, you won't have any problems at all. Just some time with a deep 10MM and a few of his friends.
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  #3  
Old 11-24-2009, 06:47 AM
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Thanks for the heads up SLT kota!
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  #4  
Old 11-24-2009, 09:32 AM
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Quote:
Originally Posted by SLT kota View Post
I haven't done that exact swap but I've been much further into it with the supercharger/manifold. It really isn't to bad but just will take you a while your first time. I'd plan a good part of a day if your doing it for the first time but realistically it can be done much faster (the first time with anything always seems to take 3 times a long)

The thing that sucks the most is that you are probably going to have to pull the heater lines, this really isn't a big problem but you will end up getting coolant everywhere (and I personally don't like it, especially cause I always have to end up laying in it after spilling it all over the garage lol)

I would drain as much coolant from the radiator as possible but you will still end up having it spill when you pull the heater lines. Not a big deal, just be prepared for it with something to clean it up.

If you aren't afraid to get dirty, you won't have any problems at all. Just some time with a deep 10MM and a few of his friends.
What heater lines will he need to move? I dont recall any heater lines in the way... perhaps its a Dakota thing but I have never heard of it till today.

From what I remember you will need to move the fuel rail with injectors... Just screws each side and then just swing the fuel rail over to the drivers side... I would not even bother disconnecting the fuel line. Then just swap the intake out. And put the fuel rail/injectors back in place. Its only a 20-30min job tops.

I have been known to over simplify things though... But I have had mind off a good 15-20 times and I have also installed a few for customers.

You will absolutely LOVE that 03 intake over your 2001 Intake.

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  #5  
Old 11-25-2009, 12:06 AM
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the dakotas have a heater hoses run just infront of the TB and you may not need to take them off. When I did mine I was able to pull them out of the way, but it bearly clears it. removing them would make it a lot easier. the hardest part about doing the swap is removing all the stuff thats on top of the intake it self. I've done the swap twice now (stock 2002 to a 2003 to a 2008)and I noticed an improvement each time
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  #6  
Old 11-25-2009, 12:19 AM
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Thanks for the help guys - I might get to it this weekend but otherwise It'll be over Christmas break.
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  #7  
Old 11-25-2009, 12:19 AM
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Ah, well if you don't have to remove the heater lines it would be much less of a pain, I had to remove and reroute mine which was lots of fun.

Depending on how much experience you have it could probably be done in 20-30 minutes. I would still allow a few hours the first time. If you do have to remove the fuel rail, it is just held on by 4 bolts (8MM), then just pull it up.
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Old 11-25-2009, 06:46 AM
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Alright hopefully this won't be too big of a deal. Thanks for all the input guys.
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Old 11-25-2009, 07:51 AM
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It really isn't that bad at all, if you don't have to unhook the heater hose lines then will be easy, I would just plan for a few hours as things always seem to take longer then I plan.
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Old 11-29-2009, 07:11 AM
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Well I got the new intake on and a couple things I discovered:

The tubing on the back of my '01 intake was off to the passenger and the '03 is in the middle. Well this distance ends up screwing you on the front side where it comes about an inch short of hooking up. Also the hookup on the back of the intake is different requiring a new coupler.

The sensor on the front of the '03 intake does NOT match up with the wiring from the '01.
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Old 11-29-2009, 07:28 AM
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Are you talking about the MAP sensor? You should be able to reuse your 01 map sensor on the new intake... this way it will plug up.

PM me with any issues you are having... If anything they SHOULD be minimal and fixable with a quick trip to Autozone. But if your having any issues let me know so we can help you get them worked out.

Or just post them here... there are plenty of people here who have done the swap and can offer you good advice.

Im assuming the "TUBING" is just the PCV hose... And the "Wiring" is the MAP sensor... let us know....

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Old 11-29-2009, 07:39 AM
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Bear with me - I don't know what all the hookups are
Yes I pulled the MAP sensor from my '01 intake and put it on the '03 intake. EDIT: Had to clip off part of the plastic because the MAP sensor and the one below it bumped into each other.

As for the PCV hose, I hope it didn't get pinched in the back. What runs through there?

EDIT: There's a band of 3 plugs near the right of the TB; 2 go into the TB and the other one went into my 2001 intake...well there is no port on the 2003 intake for it. Just leave it or what?
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Last edited by Kosgey; 11-29-2009 at 07:14 PM.
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  #13  
Old 12-01-2009, 04:10 AM
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Quote:
Originally Posted by Kosgey View Post
As for the PCV hose, I hope it didn't get pinched in the back. What runs through there??
behind the intake is nothing except the firewall.

Quote:
Originally Posted by Kosgey View Post
EDIT: There's a band of 3 plugs near the right of the TB; 2 go into the TB and the other one went into my 2001 intake...well there is no port on the 2003 intake for it. Just leave it or what?
if its what I'm thinking of, 2 go into the TB and the 3rd should plug into the intake itself behind the TB.
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Old 12-01-2009, 04:21 AM
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Quote:
Originally Posted by moparsz View Post
behind the intake is nothing except the firewall.



if its what I'm thinking of, 2 go into the TB and the 3rd should plug into the intake itself behind the TB.
I know - I'm just concerned the hose got pinched against the firewall because it came straight off the back off the new manifold.

The 3rd plug WAS on the '01 manifold but I don't see a plug on the '03 - I'm sure this is the cause of my check engine light too.
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Mods: Clear corners, homebrew intake, clutch fan removal, poor man's kill switch, 2003 intake manifold, Dwight TB

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Old 12-01-2009, 04:23 AM
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Quote:
Originally Posted by Kosgey View Post
I know - I'm just concerned the hose got pinched against the firewall because it came straight off the back off the new manifold.
There should be enough room behind it that its not pinched. I wish I still had my 03 intake so I could look exactly where mine hooked into it, but I sold it months ago
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