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Ok I couldn't find any information on the forum about a rebuild just for the magnum intake manifold so here goes.

I recently bought a mag intake manifold and I was wondering the.following things:

1. What is a good way to clean and shine the manifold to look more polished.
2. What is the part number for the gasket between the runners and the butterfly valve housing and the manifold and the block.
3. Are the fuel injectors the same from all the models of car. And which are better for a atx magnum set up.
4. Lastly what bolts are needed for the head I've heard that the bolts on the plasic manifold are too small. And I've counted 8 bolt holes on the mag intake are all of them used or just some.

Any good aluminum polish works well to shine it up a bit, or you could sand it down and really polish it. The injectors are all the same for 2g neons, excluding the srt.

I thought I once read that the 2001+ Neons had revised injectors, with a slightly different flow rate ?? The change had something to do with the switch to the 58PSI fuel pressure regulator, for the 2001+ model year, If I Recall Correctly.

Hopefully, one of the other knowledgeable folks ( Bill, or John ? ) can confirm this.



- Nick

thanks on the polish idea any clue on sand paper grits to get a good shine.

From what I have read '98 and up injectors are the same...

But I have also wondered about the pressure difference. Unless the PCM's are able to manage that with pulsewidths.

There should be a PN list for the Mag IM parts in the PN section.

thanks ill take a look

viewtopic.php?t=29860

Just in case.

that link is unclear and confusing to me.

here are a couple other links that will help for part #'s

viewtopic.php?t=51393

viewtopic.php?t=11858&highlight=gasket+part+number

viewtopic.php?p=136906#136906

any other help will be great.

orangeneon05 wrote:thanks on the polish idea any clue on sand paper grits to get a good shine.

To get the intake to shine, you will need to make the manifold smooth first. Start with 80 grit and work your way up to 2000. You will want to get a Dremel for grinding down the casting marks and extra flashing. After that, it's time to start polishing.

Expect to spend around 60 hours on this to make it look like mine. Most people give up long before that point though.

ill put the time in because i plan to put it on around august. and if you dremel down the extra metal around the injectors wont that make the intake less stable. i can understand the stamping marks because the are not there for structure.

let me know what you think.

orangeneon05 wrote: and if you dremel down the extra metal around the injectors wont that make the intake less stable.

let me know what you think.

Do you mean the webs on the outside of the runners?

As long as you use the bottom bending strut, it should be fine. It is under $12 at the dealer if you don't have one. A few Magnum IMs have cracked recently, and the strut was not used. These were non modified also.

viewtopic.php?t=60530

Remove the zero from the beginning of the PN to be correct. Some parts ppl aren't smart enough, and will tell you it is not the correct number.

yea the webs on the top of the runners. and ill look for that bracket

You don't need to remove all of the webbing. There is a lot of extra material that can be removed safely though.

Here are some pics I took during the grinding stage.





What they look like before polishing...note the excess removed near the bolt holes.



It's a good idea to keep the material intact under the runners.



What the final product can look like...

thanks dante thats what i was looking for that last one where you can see the top webs. i thought that was alot of structural metal to remove and be no bueno if you did remove it. do you coat it with anything after all the sanding besides polish so it wont rust or will it be rust free with out maintenance.

Well, it's aluminum, so no worries about rust

I did not coat it with anything. I have to keep it clean and keep it polished to maintain the finish. If it was good enough to my eyes, I would have it powdercoated clear. Alas, it isn't good enough for my OCD.

haha and thats all the way to 2000 grit

Beyond actually. Once I was done with the paper, I started with rubbing compound, went to polishing compound, then finished with dry buffing. It's just that some places need more base work before I call it good.

gotcha. so i called and got a PN for the gaskets can anyone confirm that this is two gaskets or just one.

PN=4648623AB

That is the part number for the gasket to the head. It is an one piece gasket, unlike the non Magnum manifold.

4648623AB gasket for the runners to the head (need 1)

4884067AB gasket that goes inbetween plenum & butterflies / runners
(need 1)

bingo bango just what i need. time to get a shopping list together and buy parts. thanks for all our help man.

if i put a picture up of the injector gaskets is there any way you can tell if they are bad and what this part is that i dont know if i need.

The injector o rings are dirt cheap. May as well just put new ones on. You can get them anywhere. Tho if you can find the blue ones, they seem to be a better quality. IDK what brand they are tho.

what about the plastic tips after the o rings.

Anything other than the o rings is part of the injector.

ok even though they came off.....

Got any way to post pics?

yea i do i just wanted to see before i did it because im a tiny bit lazy...... hahah

Just want to be sure we are on the same page. Hard to know exactly if we are thinking of the same thing.

If you buy a Felpro gasket for the rt intake manifold it includes the plenum gasket.

INVUJerry wrote:If you buy a Felpro gasket for the rt intake manifold it includes the plenum gasket.

do you have a part number or a website to order it.