Lower Intake Manifold

NOTE: Turbo charged engines could be equipped with either an aluminum or a plastic manifold.

Fig 1: Lower Intake Manifold Seals - Naturally Aspirated Engine

Courtesy of DAIMLERCHRYSLER CORP.

1 - SEALS

Clean all gasket surfaces.
Naturally Aspirated Engine: Position new seals on lower intake manifold. See Fig 1.
Turbocharged Engine: Replace lower intake manifold gasket.

Fig 2: Lower Intake Manifold Tightening Sequence
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Naturally Aspirated Engine: Install lower intake manifold. Tighten fasteners to 12 N.m (105 in. lbs.) in sequence shown in Fig 2.

Turbocharged Engine: Install lower intake manifold. If equipped with an aluminum manifold, tighten fasteners to 28 N.m (250 in. lbs.) in sequence shown. See Fig 2. If equipped with a plastic manifold, tighten fasteners to 12 N.m (105 in. lbs.) in sequence shown. See Fig 2

Fig 3: Lower Intake Manifold Support Bracket - 2.4L Turbo

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1 - UPPER INTAKE MANIFOLD

2 - LOWER INTAKE MANIFOLD

3 - SUPPORT BRACKET

4 - DIPSTICK TUBE SCREW

Turbocharger Equipped Engine: Install fasteners for lower intake manifold support bracket (3). See Fig 3. If equipped with an aluminum manifold, torque fasteners to 54 N.m (40 ft. lbs.). If equipped with a plastic manifold, torque manifold fasteners to 6 N.m (55 in. lbs.).

Fig 4: FUEL LINE CONNECTION - 2.4L TURBO
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If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 N.m (200 in. lbs.).
Connect fuel injector wiring harness.

Inspect quick connect fittings for damage, replace if necessary (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) . Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.

Fig 5: Dipstick Tube

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1 - DIPSTICK TUBE

2 - COOLANT TEMPERATURE SENSOR

3 - SCREW

Install the screw attaching the oil dipstick tube to lower intake manifold. See Fig 5.

Fig 6: Thermostat and Coolant Outlet Connector

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1 - TIMING BELT COVER

2 - OUTLET CONNECTOR

3 - THERMOSTAT

4 - THERMOSTAT HOUSING

Install thermostat (3) and coolant outlet connector (2). See Fig 6 (Refer to COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - INSTALLATION) .

Fig 7: RADIATOR HOSE
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1 - UPPER RADIATOR HOSE

2 - LOWER INTAKE MANIFOLD
Install radiator upper hose (1).
Install upper intake manifold (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD UPPER - INSTALLATION) .

Fig 8: Battery-Removal/Installation
Courtesy of DAIMLERCHRYSLER CORP.

1 - BATTERY
Connect negative cable to battery (1).
Fill the cooling system (Refer to FILLING COOLING SYSTEM - 2.0L/2.4L ENGINE ).
With the DRBIII® 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.
Start engine and check for leaks.