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View Full Version : DIY 6.1 Intake manifold on 5.7



grim300c
04-13-2013, 02:17 AM
Heres a quick write up on a 6.1 Intake manifold installation on a 5.7. Theres alot of info on this but i couldnt find it all together. So it might be helpful for those trying to tackle this on their own. Thanx to Darknight for coming over and lending a hand.
Heres a list of what is needed on a stock 5.7
-6.1 INTAKE MANIFOLD
-6.1 FUEL RAIL
-6.1 to 5.7 ADAPTER PLATES FROM MODERN MUSCLE PERFORMANCE
-6.1 PVC VALVE
-6.1 MAP SENSOR
-EGR DELETE PLATE KIT FROM BILLET TECH and CUSTOM TUNE DISABLING THE SENSOR.
-FUEL RAIL BOLTS: 6mmx1.0 x 25mm
-INTAKE MANIFOLD BOLTS: 6mm X 1mm X 35mm


First you need to depressurize the fuel system by removing FUSE #6(20amp) in trunk fusebox,
then crank engine to release pressure. Engine might start but will shut off.


Install custom tune and then unplug battery to prevent damage to electrical system while you are working on it.
Remove EGR valve. Heres a link to a write up for those who havent done this before.
HOW TO ...install EGR DELETE (pic heavy) - Dodge Charger Forum - Forums and Owners Club! (http://www.chargerforumz.com/showthread.php?t=79656)


Disconnect the fuel injector wires and move harness out to the side. Disconnect MAP sensor plug and all vacuum line connected to manifold. I couldnt disconnect the vacuum line on the back of the manifold so i disconnected from the brake booster.
http://i56.photobucket.com/albums/g164/racereh04/cannon010_zps14225c2f.jpg (http://s56.photobucket.com/user/racereh04/media/cannon010_zps14225c2f.jpg.html)
http://i56.photobucket.com/albums/g164/racereh04/cannon002_zpscace0970.jpg (http://s56.photobucket.com/user/racereh04/media/cannon002_zpscace0970.jpg.html)
Remove 10 bolts holding down intake manifold, and remove manifold. this would be a good time to get a shop vac and suck up any debris that might fall into head ports. Also wipe down the area.
http://i56.photobucket.com/albums/g164/racereh04/cannon011_zpsed362069.jpg (http://s56.photobucket.com/user/racereh04/media/cannon011_zpsed362069.jpg.html)
Install billet adapter plates.
http://i56.photobucket.com/albums/g164/racereh04/cannon012_zpsd94acfab.jpg (http://s56.photobucket.com/user/racereh04/media/cannon012_zpsd94acfab.jpg.html)
Remove fuel injectors from 5.7 fuel rail and install them on the 6.1 fuel rails. Also remove plastic lock clip and install it on the 6.1 fuel rail.
http://i56.photobucket.com/albums/g164/racereh04/cannon013_zps26aba25d.jpg (http://s56.photobucket.com/user/racereh04/media/cannon013_zps26aba25d.jpg.html)
http://i56.photobucket.com/albums/g164/racereh04/cannon015_zps4d6f933a.jpg (http://s56.photobucket.com/user/racereh04/media/cannon015_zps4d6f933a.jpg.html)
Install fuel rails,PVC valve and MAP sensor on the 6.1 manifold. Position intake manifold and install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a crisscross pattern. Torque fasteners to(124 in. lbs.). this is a lil more than hand tight. its not ft. lbs. so dont snap your bolts.
http://i56.photobucket.com/albums/g164/racereh04/cannon016_zpsb3227467.jpg (http://s56.photobucket.com/user/racereh04/media/cannon016_zpsb3227467.jpg.html)
http://i56.photobucket.com/albums/g164/racereh04/cannon017_zpsb1aa5064.jpg (http://s56.photobucket.com/user/racereh04/media/cannon017_zpsb1aa5064.jpg.html)
Reconnect wires to fuel injectors and MAP sensor.
This vacuum line is different on the 6.1. so for now i used a clamp to hold it in place until im able to reroute it under the manifold.
http://i56.photobucket.com/albums/g164/racereh04/cannon024_zpse0bf53cf.jpg (http://s56.photobucket.com/user/racereh04/media/cannon024_zpse0bf53cf.jpg.html)
The wire to the throttle body connector wasnt long enough the way i routed the harness so i had to extend it.
http://i56.photobucket.com/albums/g164/racereh04/cannon021_zps9b858a49.jpg (http://s56.photobucket.com/user/racereh04/media/cannon021_zps9b858a49.jpg.html)


Install intake inlet tube. IAT sensor, and reconnect fuel pump fuse if you havent done so yet.

Double check all the connectors and vacuum lines to make sure they're all reconnected. Reconnect the battery and start her up. If all went well, you should have a smooth idle. Give yourself a pat on the back and have a beer.
http://i56.photobucket.com/albums/g164/racereh04/cannon027_zps62adb82b.jpg (http://s56.photobucket.com/user/racereh04/media/cannon027_zps62adb82b.jpg.html)

If anybody notices anything i missed, feel free to add on to it.

Blueturd
04-13-2013, 09:53 AM
Green Beans to you! Great and much needed write up and gorgeous car!

ZXThunder
04-14-2013, 10:51 AM
Holy moly. Nice write up!!! Did you pick up everything used off a srt? Or did you buy a lot of the parts new? Also, what exhaust manifolds are you running?

dejuan71
04-14-2013, 11:18 AM
Nice i imagine nicer topend??

Mighty Noid
04-14-2013, 11:52 AM
48832

SRTJohn & Myself did this yesterday to Dupie24 2005 Magnum yesterday...

We added a few more items also... BT valve & coil covers, S&P bolt kit & SRTJohn special hard lines for the BT catch can...

Firewall and cleaning up the wiring is coming in another week or so...

EMMJAY
04-14-2013, 12:13 PM
Is custom tuning needed for this? (besides to shut off the EGR)

grim300c
04-14-2013, 12:44 PM
Holy moly. Nice write up!!! Did you pick up everything used off a srt? Or did you buy a lot of the parts new? Also, what exhaust manifolds are you running?
I bought intake manifold and fuel rails used of other forum members. the sensors an bolts were pretty inexpensive. for headers, I have Doug thorley shorties. as far as top end, I love it but it seems like it lost some bottom end power.

grim300c
04-14-2013, 12:46 PM
48832

SRTJohn & Myself did this yesterday to Dupie24 2005 Magnum yesterday...

We added a few more items also... BT valve & coil covers, S&P bolt kit & SRTJohn special hard lines for the BT catch can...

Firewall and cleaning up the wiring is coming in another week or so...
looks great. big difference

hecatomb
04-14-2013, 12:52 PM
Just curious why the throttle body connector was long enough for MightyNoid but not Grim300c. Also, was the vacuum line a tight fit for you mighty like it was for grim?

Mighty Noid
04-14-2013, 02:07 PM
The throttle body wires were short/tight but Dupie decided to run the wire next to the fuel rail and not down by the valve covers... That gave us plenty of length...

The vacuum line was a bit short... Just cut it and extended it with more hose... Very simple... Plus we ran it under the intake... To make it look nice... Also the manifold was tap for better fittings... Just added more detail to the engine area...

Plus one more major thing we did... Removed the single coil packs and ugly ass wires... Went with new dual pack coils and new connectors...

New wire loom will be done soon...

Also if you have an older version on your diablo like R18 or older.. It has the egr delete feature on it... If you have a newer version... You will need to get a custom tune to just turn that part off... Unless you like the the check engine light on all the time...

Mighty Noid
04-14-2013, 02:20 PM
48842

48843

48844

hecatomb
04-14-2013, 03:35 PM
The throttle body wires were short/tight but Dupie decided to run the wire next to the fuel rail and not down by the valve covers... That gave us plenty of length...

The vacuum line was a bit short... Just cut it and extended it with more hose... Very simple... Plus we ran it under the intake... To make it look nice... Also the manifold was tap for better fittings... Just added more detail to the engine area...

Plus one more major thing we did... Removed the single coil packs and ugly ass wires... Went with new dual pack coils and new connectors...

New wire loom will be done soon...

Also if you have an older version on your diablo like R18 or older.. It has the egr delete feature on it... If you have a newer version... You will need to get a custom tune to just turn that part off... Unless you like the the check engine light on all the time...

Good to know. Btw, the pic links don't work

Mighty Noid
04-14-2013, 04:16 PM
48861

48862

48863

Hal'sMag
04-14-2013, 09:31 PM
I like the color theme Dupie sticks with. I'm surprised Tina didn't insist on a palm tree???

Congrats to one of my favorite SoCalLX couples!

ZXThunder
04-14-2013, 11:50 PM
What was the total cost of parts to complete this swap? Do you have a before and after video of what it sounds like?

Hal'sMag
04-15-2013, 12:03 AM
OOPS, sorry Noid, didn't see the tree. One of the most detail oriented cars out there.

It's the attention to detail!

Mighty Noid
04-15-2013, 12:09 AM
What was the total cost of parts to complete this swap? Do you have a before and after video of what it sounds like?

The one that we did.. I'm afraid to add it up...
It's most likely around 3500 without the labor...

Didn't change the sound at all outside the car... The sound inside did change a bit... You can hear all the air coming for the huge air filter... For the better

DaKing
04-15-2013, 12:19 AM
How did you get the hard line to connect to the PVC, and does the PVC pipe on the intake just come off? Do you have to Tap dat ho, when you take that stub pipe out?

Thanks


48861

48862

48863

grim300c
04-15-2013, 12:21 AM
What was the total cost of parts to complete this swap? Do you have a before and after video of what it sounds like?

The basic parts list is on the first post so you could do it for cheaper if you shop around for used parts, but just like Noid commented, things do add up quick especially if you want a polished intake and nice valve covers to complete the look. I polished my own, and to be honest it wasnt a walk in the park. Its alot of work to polish so its safe to say that the price of a polished unit is pretty reasonable.

Mighty Noid
04-15-2013, 12:35 AM
How did you get the hard line to connect to the PVC, and does the PVC pipe on the intake just come off? Do you have to Tap dat ho, when you take that stub pipe out?

Thanks
SRTJohn did that part... I know he tapped the hole and I know he took a fitting and cut it up and made the two pieces fit together...
Here's an image:
48866

ponch79
04-16-2013, 11:01 PM
Why can't you just port match the 5.7 heads to the 6.1 manifold instead of using adapters ???

DaKing
04-16-2013, 11:48 PM
Thats What I did, Port matched.

6.1 Block, 5.7 BV Heads, 6.1 Intake.

Although, I think the adapters may help me in clearance issues, I'd like to rise my Throttle Body a fraction on an inch.

http://i716.photobucket.com/albums/ww166/dkingery/HEMI_RAM/426HEMI/IMAG0205_zps0cf14e7f.jpg (http://s716.photobucket.com/user/dkingery/media/HEMI_RAM/426HEMI/IMAG0205_zps0cf14e7f.jpg.html)

http://i716.photobucket.com/albums/ww166/dkingery/HEMI_RAM/426HEMI/IMAG0203_zpsd8c5eaa1.jpg (http://s716.photobucket.com/user/dkingery/media/HEMI_RAM/426HEMI/IMAG0203_zpsd8c5eaa1.jpg.html)

Mighty Noid
04-16-2013, 11:49 PM
It's cheaper and quicker to get done...

Not everyone can do that type of machine work... Plus if you can do it that way... I'm sure your car will be down a lot longer than a few hours...

BlackAce
04-17-2013, 06:30 AM
Wow nice wrote up. I'm looking into doing this. I have everything just need the adapters. I'm guessing you can using the bolt from the 5.7 intake?

One suggestion though, on the pics why not upload them to LXforums instead of photobucket. That way they won't be deleted or shut down due to traffic and a couple months from now when others need this the pics will still be up.

grim300c
04-17-2013, 10:31 PM
Wow nice wrote up. I'm looking into doing this. I have everything just need the adapters. I'm guessing you can using the bolt from the 5.7 intake?

One suggestion though, on the pics why not upload them to LXforums instead of photobucket. That way they won't be deleted or shut down due to traffic and a couple months from now when others need this the pics will still be up.

you cant use the bolts on the 5.7 manifold. those are specially made for that manifold. i didnt know you can upload pics to lxf. do we do that when were writing the post? ill look into that thanx.

BlackAce
04-19-2013, 12:16 PM
Yea you can there should be a picture link so you can upload then from your computer

Charged_Up
05-24-2013, 12:32 PM
Are the adapter plates required for my 2012 5.7L? I have a couple of leads on Intake Manifolds, but the adapter plates are > $300!

notton_08
05-24-2013, 12:51 PM
Are the adapter plates required for my 2012 5.7L? I have a couple of leads on Intake Manifolds, but the adapter plates are > $300!

No plate required.

Charged_Up
05-24-2013, 12:57 PM
No plate required.

Perfect! About how much power does this free up? I'm seriously considering this upgrade...

notton_08
05-24-2013, 01:00 PM
Perfect! About how much power does this free up? I'm seriously considering this upgrade...

It's been debated, you'll likely lose power mid range, but gain on top range. This mod is more for looks than power for the eagle motors. The 05-08 blocks will get a little performance out of this, but will benefit more with an eagle head, IMO.

Dr. Bud
05-24-2013, 01:50 PM
If someone else with an 05 wanted a similar look without costing as much, I know someone who's selling a shaved & ready to paint 5.7 manifold, 6.1 fuel rails, shorty wires, and metal (05) valve covers....

http://www.lxforums.com/board/f57/intune-5-7-manifold-6-1-fuel-rails-taylor-shorty-wires-blue-05-valve-covers-335603/

Just saying ;)

BTW, That looks fantastic!

MattRobertson
05-24-2013, 01:54 PM
What a great thread. Moving it to the Knowledge Base for posterity.


Why can't you just port match the 5.7 heads to the 6.1 manifold instead of using adapters ???


Thats What I did, Port matched.Me too. My first stroker was a 5.7-based 390 with a 6.1L intake matched to the 5.7 heads. As Al says... it sure wasn't down for a few hours to get that done. If I had used spacers the manifold would not have fit under my strut bar.


... on the pics why not upload them to LXforums instead of photobucket. That way they won't be deleted or shut down due to traffic and a couple months from now when others need this the pics will still be up.Uploading pics to LxF is much more awkward, and more restrictive. The pics are lined up in reduced size at the bottom of the post, not inline with the story. If you upload a pic thats bigger than the forum max (I forget what it is but its not a lot) then the forum will resize them down. And you can only upload so many photos in total before you have to go back and delete something old so you can keep uploading.

Uploading to LxF really is something you should be doing as a last-ditch effort. Almost everyone uses linking like the OP did and you'll find posts here that are years old with pics still working fine. I think for forum-going types its a given that we all have some long-term method of serving up pics. Me, I have my own servers, but most people use Photobucket, free or paid, and it works just fine.

http://foohbar.com/ul/modhat.gif

Dr. Bud
05-24-2013, 01:57 PM
^^Or you can do what I've done for a few things in the KB. Copy & paste and save as a PDF.

ejshemi527
09-20-2013, 08:29 PM
Dumb question but are the 6.1 manifold gaskets needed? Huey are not listed on the first post.

nascarpat24
09-20-2013, 08:58 PM
Get the pink 6.1 intake gaskets from Indy Cylinder Head. They are just over $30 dollars plus shipping. I have an extra set if you want to do $30 shipped.

BlackAce
09-20-2013, 09:16 PM
I did the swap and didn't use 6.1 gaskets. I pretty sure MM adapters are designed to use Orings without issues.

nascarpat24
09-21-2013, 04:15 PM
I used the pink gaskets because my heads were port matched to the intake. I believe the mm adapters are for heads that are not port matched to help with the transition of air from intake to heads.

ejshemi527
09-21-2013, 08:40 PM
I used the pink gaskets because my heads were port matched to the intake. I believe the mm adapters are for heads that are not port matched to help with the transition of air from intake to heads.


Im Gonna Have To Use The Mm Adapters Because My Heads Are Not Porte. If Im Using The Adapters I Dont Need The Gaskets?

grim300c
09-21-2013, 09:45 PM
Correct. If using adapters, then you dont need gaskets.

ejshemi527
09-21-2013, 11:23 PM
Correct. If using adapters, then you dont need gaskets.


Sweet thanks!