Upgrading the intake manifold on a Mopar 440 is one of the most effective ways to unlock horsepower and torque. The Edelbrock Performer RPM is a dual-plane intake designed for high-performance street and mild race applications, delivering a significant boost in mid-range and top-end power. This guide provides a comprehensive, step-by-step installation process for the Edelbrock Performer RPM on your Mopar 440, covering everything from preparation to final tuning. Whether you are a seasoned gearhead or a confident DIY enthusiast, following these instructions will help you achieve a clean, leak-free installation that maximizes engine performance.

Tools and Materials Needed

Before starting, gather all necessary tools and components. Having everything on hand will prevent delays and ensure a smooth workflow.

  • Edelbrock Performer RPM intake manifold (part #7199 for standard port, #7599 for Mopar 440 with oval ports)
  • Intake manifold gasket set (recommended: Fel-Pro #1270 or equivalent)
  • Valve cover gaskets (optional, if removal is needed)
  • Torque wrench (ft-lb and in-lb ranges)
  • Socket set with extensions (3/8" and 1/2" drive, metric and SAE)
  • Ratchet and breaker bar
  • Gasket scraper (plastic or brass preferred to avoid scoring)
  • Engine degreaser or carburetor cleaner
  • Shop towels and rags
  • Thread sealant (Permatex or Loctite) for intake bolts that enter water jackets
  • Anti-seize compound for bolt threads
  • RTV silicone gasket maker (for china rails and water passages if needed)
  • Carburetor and air cleaner assembly (or temporary plugs to keep debris out)
  • Feeler gauges (to check distributor gear mesh if distributor is disturbed)
  • Allen wrenches (for some bolt heads)
  • Safety glasses and nitrile gloves

Preparation Steps

Proper preparation is critical. A rushed installation often leads to leaks, warped gaskets, or even engine damage. Follow these steps carefully.

Engine and Work Area Setup

  • Cool down the engine: Ensure the engine is completely cold to the touch. Working on a hot engine can cause burns and makes gasket removal difficult.
  • Disconnect the battery: Remove the negative battery cable to prevent accidental short circuits or fuel pump activation.
  • Drain coolant (if needed): The intake manifold crossovers coolant from the cylinder heads. If you are not removing the entire coolant system, drain the radiator and block to prevent coolant spillage into the engine valley. A 50/50 mix of antifreeze and water can be collected and reused.
  • Remove air cleaner and carburetor: Disconnect the throttle linkage, fuel line, and vacuum hoses. Label each hose if necessary. Remove the carburetor and set it aside on a clean surface. Plug the fuel inlet and vacuum ports to keep debris out.
  • Identify and remove ancillary components: This may include the distributor (mark position accurately for reinstallation), spark plug wires, ignition coil, heater hoses, and any brackets that cross the intake. Take photos before disassembly for reference.
  • Clean the engine valve covers: If they obstruct manifold removal, take them off. Clean the gasket surfaces thoroughly.

Cleaning the Existing Intake Surface

Old gasket material, silicone, and oil residue must be completely removed. Use a plastic scraper to avoid damaging the aluminum heads or block. Follow up with engine degreaser and a clean shop towel. The surface must be smooth and dry before installation.

Pro tip: For stubborn gasket residue, use a gentle abrasive pad (like a Scotch-Brite) with care. Avoid steel wool or sandpaper, which can leave grit that may cause sealing issues.

Removing the Old Intake Manifold

With the engine prepped, remove the existing intake.

  • Remove intake bolts: Using a socket and ratchet, remove all bolts in a reverse of the tightening sequence (starting from the center and working outward) to prevent warping the manifold.
  • Break the seal: If the manifold is stuck, use a rubber mallet or a pry bar carefully at the corners. Do not pry against the mating surfaces of the heads.
  • Lift the manifold: With assistance (the Edelbrock Performer RPM weighs about 25 lbs), lift straight up. Watch for the distributor hold-down clamp and oil pump driveshaft if the distributor is still in place.
  • Inspect the valley: Once removed, inspect the lifter valley for debris or coolant. Clean any residue with rags and compressed air. Place a clean shop towel over the lifter valley openings to prevent foreign objects from falling in.
  • Check head and block surfaces: Ensure no old gasket material remains on the cylinder heads or the block front/rear sealing rails. Clean again if necessary.

Preparing the Edelbrock Performer RPM for Installation

Before bolting on the new manifold, take time to prepare it.

  • Inspect the manifold: Check for casting flash or rough spots on the runner openings. Smooth them with a fine file if desired, but avoid changing the port shape.
  • Check water crossover passages: The Edelbrock Performer RPM includes a coolant crossover passage. Ensure the gasket set includes a water neck gasket (most Mopar 440s use a thermostat housing on the intake). Verify compatibility with your cylinder head coolant ports (some Edelbrock intakes may require block-offs if heads have different port configurations).
  • Clean the manifold: Wash the intake with warm soapy water to remove any manufacturing oils or grit. Rinse thoroughly and dry with compressed air. Do not use solvents that may leave a residue.
  • Mock-up the distributor (if applicable): If you removed the distributor, now is a good time to ensure the distributor gear meshes correctly with the camshaft. With the manifold loosely in place, check that the distributor seats fully. The Edelbrock Performer RPM is designed for a standard distributor location, but clearance should be verified.

Installing the Edelbrock Performer RPM Intake Manifold

Now for the critical installation. Follow the manufacturer's torque specifications and sequence.

Applying Gaskets and Sealant

  • Install the valley pan gasket (if using one): Many Mopar 440s use a valley pan gasket that seals the lifter valley and provides a mounting surface for the intake gaskets. If your gasket set includes one, place it carefully, ensuring alignment with the head bolt holes and water passages.
  • Place intake port gaskets: Use the correct gaskets for your cylinder head port shape (oval or rectangular). Edelbrock provides gaskets with the manifold, but aftermarket Fel-Pro gaskets are often preferred for their durability. Apply a thin bead of RTV silicone around the water passages and at the ends of the gasket (china rails) as recommended. Do not use excessive silicone; a 1/8" bead is sufficient.
  • Apply thread sealant to intake bolts: Some intake bolts on the 440 enter the water jacket. Use a non-hardening thread sealant on those bolts (check service manual). For bolts that do not enter water, use anti-seize for future removal.

Setting the Manifold in Place

  • Lower the manifold carefully: With assistance, align the manifold over the dowel pins (if present) or over the gaskets. Avoid sliding the manifold sideways, which can displace the gaskets.
  • Start all bolts by hand: Insert all intake bolts and run them down finger-tight. Ensure each bolt is threaded correctly and not cross-threaded.
  • Tighten in stages using the correct sequence: The Edelbrock recommended torque for the Performer RPM is 25 ft-lb in two or three steps. Use a crisscross pattern starting from the center and moving outward. Refer to the diagram provided with the manifold. A typical sequence for a V8 intake is: center bolts first, then outward, then front and rear.
Recommended tightening sequence for Edelbrock Performer RPM on Mopar 440 (bolts numbered from front to rear, left to right).

Torque sequence (example): 1, 2, 3, 4 in center; then 5, 6, 7, 8 next outward; then 9, 10, 11, 12 front and rear. Always follow the manufacturer's included diagram. After initial torque to 15 ft-lb, re-torque to 25 ft-lb in the same order. Wait 10 minutes and check again.

  • Re-torque after a heat cycle: After the engine has been run and cooled, check bolt torque again. This ensures gasket compression stabilizes.

Reconnecting Components

With the manifold securely installed, reconnect peripherals.

Distributor Installation

If you removed the distributor, align the rotor to the position you marked. On a Mopar 440, the distributor gear must mesh correctly with the camshaft. Use a feeler gauge to check gear clearance if needed (typically 0.010"–0.020"). Install the distributor hold-down clamp and tighten.

Carburetor and Linkage

  • Mount the carburetor: Use a new carburetor base gasket. The Edelbrock Performer RPM has a standard square-bore mounting flange (4-bbl). If your carb is a spread-bore, you may need an adapter.
  • Connect fuel line and vacuum hoses: Ensure all connections are tight. Use fuel line clamps on rubber hoses. Connect vacuum hoses according to your vehicle's configuration (power brakes, vacuum advance, etc.).
  • Throttle and kickdown linkage: Adjust the throttle cable or rod to allow full throttle opening. If you have a Chrysler automatic transmission, ensure the kickdown linkage is correctly adjusted to prevent transmission damage.

Cooling System

  • Reconnect heater hoses and bypass hoses.
  • Install thermostat and housing: Use a new gasket. Fill the cooling system with the proper coolant mixture. Leave the radiator cap off temporarily to allow air to escape.

Air Cleaner and Other Accessories

  • Attach the air cleaner housing. Ensure clearance with the hood. The Edelbrock Performer RPM is slightly taller than some iron intakes; you may need a drop-base air cleaner or a hood spacer if using a tall air filter.
  • Reinstall any brackets, such as alternator or A/C compressor brackets, that were removed.

Final Checks and Initial Start-Up

Before turning the key, perform a thorough inspection.

  • Reconnect the battery.
  • Check all bolts and clamps: Ensure intake bolts are at proper torque, fuel lines tight, and vacuum hoses connected.
  • Look for leaks: Visually inspect the intake manifold gasket area for any signs of coolant or oil weep. The front and rear seals should be dry.
  • Prime the oil system: If the engine has been sitting or if you exposed the lifter valley, it's wise to prime the oil system by running the starter with the ignition disconnected until oil pressure registers (or use a priming tool).
  • Start the engine: Turn the key and let it idle. Monitor the temperature gauge, oil pressure, and listen for any vacuum leaks (hissing). If the engine idles roughly, check for vacuum leaks around the carburetor base or intake gaskets.
  • Check for coolant leaks: With the engine warmed up, check all water connections. Tighten hose clamps as needed. Burp the cooling system if air pockets are present.
  • Test drive: After confirming no leaks, take a short drive. Vary the engine speed to seat the rings and check for proper power delivery. The Edelbrock Performer RPM should provide a noticeable improvement in mid-range torque and top-end horsepower.

Performance Expectations and Tuning Tips

The Edelbrock Performer RPM is designed for engines with moderate camshafts and high-performance street use. On a Mopar 440, you can expect power gains of 15–30 hp typically, with improved throttle response. For best results:

  • Carburetor tuning: The Performer RPM works well with 600–800 CFM carburetors. A 750 CFM Edelbrock or Holley carburetor is a common match. Adjust idle mixture and timing for optimal vacuum and throttle response.
  • Ignition timing: Expect initial timing of 12–16 degrees BTDC, with total timing around 34–38 degrees by 3000 rpm. Use a vacuum advance that pulls out at light throttle (ported or manifold vacuum depending on setup).
  • Exhaust system: To fully utilize the intake, ensure free-flowing exhaust headers (at least 1-3/4" primary tubes) and a low-restriction dual exhaust system.
  • Cooling: If your 440 runs hot, consider a high-flow water pump and a larger radiator. The aluminum intake dissipates heat better than cast iron.

Common Pitfalls and Troubleshooting

  • Coolant leaks at intake gaskets: Usually caused by improper cleaning or insufficient torque. Re-torque bolts in sequence after heat cycle. If leaks persist, the gaskets may need replacement.
  • Oil leaks at front/rear china rails: Apply RTV silicone generously at the corners where the intake meets the cylinder head. Use the recommended gasket or a dedicated rail gasket.
  • Distributor interference: Some aftermarket distributors may hit the intake runner. If so, a small amount of material can be ground from the manifold (avoid water passages). Alternatively, use a shorter distributor.
  • Hood clearance: Measure before final assembly. Use a drop-base air cleaner or a hood scoop if needed.

Conclusion

Installing an Edelbrock Performer RPM intake on your Mopar 440 is a rewarding project that can significantly enhance your engine’s power and drivability. By following this detailed guide and paying careful attention to surface preparation, gasket sealing, and torque procedures, you can achieve a reliable, high-performance installation. Always refer to the manufacturer's instructions and consult authoritative resources like Edelbrock for specific specifications. For community advice and real-world experiences, forums such as For B Bodies Only and Moparts are invaluable. Take your time, work safely, and enjoy the new performance from your Mopar 440.