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Intake Manifold: Installation

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install new intake manifold and gasket. Gradually tighten fasteners to 28 N.m (250 in. lbs.) in sequence shown in Fig 1.
  2. Install coolant outlet connector (Refer to COOLING/ENGINE/COOLANT OUTLET HOUSING - INSTALLATION) .
  3. Install fuel rail.
  4. Install fuel rail support bracket. See Figure.
  5. Connect previously disconnected electrical connectors.
  6. Install fastener holding fuel rail bracket to side of cylinder head.
  7. Inspect quick connect fittings for damage, replace if necessary. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
  8. Connect vacuum hoses to intake manifold.
  9. Install engine oil dipstick and tube.
  10. Install EGR tube (if equipped).
  11. Install throttle and speed control cables to bracket. Connect cables to the throttle lever.
  12. Fill cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE) .
  13. Connect negative battery cable.
  14. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.
Fig 1: Intake Manifold Tightening Sequence
GC0032068Courtesy of DAIMLERCHRYSLER CORP.
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