Upper Intake Manifold: Non-Turbo

Fig 1: Covering Lower Intake Manifold Openings

Courtesy of DAIMLERCHRYSLER CORP.

1 - INTAKE MANIFOLD MUST BE COVERED DURING SERVICE

If lower intake manifold was covered during service, remove cover (1).
Clean all sealing surfaces. Replace seals as necessary.
Position new seals on manifold.

Fig 2: Intake Manifold Tightening Sequence
Courtesy of DAIMLERCHRYSLER CORP.
Position upper intake manifold on lower intake manifold. Tighten upper intake manifold fasteners to 12 N.m (105 in. lbs.) in sequence shown. See Fig 2.

Fig 3: PCV & MAKE-UP AIR HOSE
Courtesy of DAIMLERCHRYSLER CORP.

1 - MAKE-UP AIR HOSE

2 - PCV VALVE
Connect PCV hose (2) to intake manifold. See Fig 3.

Fig 4: MAP Sensor
Courtesy of DAIMLERCHRYSLER CORP.

1 - MAP SENSOR
Connect manifold absolute pressure (MAP) (1) electrical connector. See Fig 4.

Fig 5: Proportional Purge Hoses
Courtesy of DAIMLERCHRYSLER CORP.

1 - PROPORTIONAL PURGE HOSES
Connect proportional purge hoses (1). See Fig 5.

Fig 6: Brake Booster Hose
Courtesy of DAIMLERCHRYSLER CORP.
Connect brake booster hose. See Fig 6.
Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.

Fig 7: Throttle Cables - 2.4L Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Install throttle and speed control cables to bracket. Connect cables to the throttle lever.

Connect negative cable to battery.

Fig 8: Clean Air Hose

Courtesy of DAIMLERCHRYSLER CORP.

1 - AIR CLEANER HOUSING

2 - INLET AIR TEMPERATURE SENSOR

3 - MAKE-UP AIR HOSE

Install air cleaner housing (1) and clean air hose. Tighten clean air hose clamp to 1.7 N.m (15 in. lbs.).
Connect make-up (3) air hose and inlet air temperature sensor (2). See Fig 8.