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Manifold - Intake: Installation: Manifold-Intake-Upper

WARNING: This page is about a different car, the 2008 Dodge Magnum, 2008 Dodge Charger, and 2008 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Intake Manifold Braces
GC0015451Courtesy of CHRYSLER LLC
1 - INTAKE MANIFOLD
2 - PENCIL BRACKETS
  1. Clean and inspect gasket sealing surfaces.
  2. Position new gasket.
  3. Install the upper intake manifold insulator foam.
  4. Install the upper intake manifold. Tighten bolts to 12 N.m (105 in. lbs.) starting in the center working outward in a cross sequence pattern.
  5. Install the right manifold support brackets. Tighten fasteners to 12 N.m (105 in. lbs.).
    Fig 2: Throttle Body Bracket
    GC0013154Courtesy of CHRYSLER LLC
  6. Install the throttle bracket. See Fig 2. Tighten fasteners to 12 N.m (105 in. lbs.) at the throttle body and 28 N.m (259 in. lbs.) at the cylinder head.
    Fig 3: Identifying Manifold Tuning Valve & Short Runner Valve
    GC0013134Courtesy of CHRYSLER LLC
    1 - Manifold Tuning Valve
    2 - Short Runner Valve
  7. Connect the manifold tuning valve and short runner valve electrical connectors.
    Fig 4: Throttle Control
    GC0015452Courtesy of CHRYSLER LLC
    1 - PCV HOSE
    2 - PURGE HOSE
    3 - BRAKE BOOSTER HOSE
    4 - THROTTLE BRACKET
    5 - ELECTRONIC THROTTLE CONTROL
  8. Connect the electronic throttle control harness connector.
  9. Connect the engine electrical connectors to the intake manifold.
    NOTE: Install new rubber silicone seals on intake manifold end of EGR tube any time it is removed from the intake manifold.
    Fig 5: EGR Tube
    GC0052750Courtesy of CHRYSLER LLC
    1 - INNER EGR TUBE SEAL
  10. Verify the upper EGR tube seal (1) is positioned correctly on the EGR tube assembly.
    Fig 6: Upper EGR Tube
    GC0052751Courtesy of CHRYSLER LLC
    1 - EGR Tube Seal
    2 - Manifold
    3 - EGR Tube
  11. Install the EGR tube (3), and verify the seal is correctly positioned in the intake manifold.
  12. Connect the PCV, Purge and power brake booster vacuum hoses to the intake manifold.
    Fig 7: Locating Manifold Absolute Pressure Sensor
    GC0013141Courtesy of CHRYSLER LLC
  13. Connect the MAP sensor harness connector.
    Fig 8: Inlet Hose
    GC0013153Courtesy of CHRYSLER LLC
  14. Install the inlet hose and connect the IAT sensor harness connector.
  15. Connect negative battery cable.
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