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Intake Manifold Upper

WARNING: This page is about a different car, the 2010 Dodge Charger and 2010 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Removing/Installing Intake Manifold Bolts
GC0081659Courtesy of CHRYSLER LLC
  1. Clean and inspect the sealing surfaces. Gaskets can be reused, if free of cuts or tears.
    NOTE: Make sure fuel injectors and wiring harnesses are in correct position to not interfere with upper manifold installation.
  2. Install the upper intake manifold gasket.
  3. Position the upper intake manifold onto the lower intake manifold.
  4. Install the manifold attaching bolts and tighten in the sequence shown in illustration to 12 N.m (105 in. lbs.).
  5. Connect the vapor purge hose, brake booster hose and Positive Crankcase Ventilation (PCV) hose.
    Fig 2: Identifying Inner EGR Tube Seal
    GC0081112Courtesy of CHRYSLER LLC
    1 - INNER EGR TUBE SEAL
    CAUTION: Do Not use metal scrapers when cleaning the mounting surface of the EGR valve. Damage from scratching the surface may cause an improper seal.
    CAUTION: Do not allow debris to enter the EGR valve when cleaning the mounting surface. Debris can lodge between the pintle and the seat causing valve leakage that results in rough idle and depressed manifold vacuum.
  6. Clean and inspect the EGR gasket sealing surfaces.
    NOTE: Install new rubber silicone seals on intake manifold end of EGR tube any time it is removed from the intake manifold.
  7. Install new silicone rubber seal (1) on the intake manifold end of the EGR tube. Position seal 17 mm (0.67 in.) from the tube flange.
    Fig 3: Identifying EGR Flange, EGR Tube & Intake Manifold
    GC0081113Courtesy of CHRYSLER LLC
    1 - Flange
    2 - Intake Manifold
    3 - EGR Tube
  8. Lubricate the EGR mounting tube hole in the intake manifold with Mopar® Rubber Bushing Installation Lube. Do not lubricate the EGR tube or seal.
  9. Install the EGR tube (3) into the intake manifold (2) being careful not to damage the silicone rubber seals, and verify that the seals are correctly positioned in the intake manifold.
    Fig 4: EGR VALVE
    GC0081108Courtesy of CHRYSLER LLC
  10. Install a new gasket between the EGR valve and the EGR tube and install bolts (2). Tighten bolts to 15 N.m (11 ft. lbs.).
    Fig 5: Identifying EGR Flange, EGR Tube & Intake Manifold
    GC0081113Courtesy of CHRYSLER LLC
    1 - EGR Tube Flange
    2 - Intake Manifold
    3 - EGR Tube
    NOTE: The EGR tube flange (1) does not need to be flush with the intake manifold (2) to be sealed. The EGR tube flange can be up to 2 mm (0.08 in.) from intake manifold and still be sealed. This design allows the EGR tube position to vary with the tolerance stack up and remain properly sealed.
    Fig 6: AIR FILTER ASSEMBLY
    GC0081601Courtesy of CHRYSLER LLC
    1 - THROTTLE BODY
    2 - CHARGE AIR TEMPERATURE SENSOR ELECTRICAL CONNECTOR
    3 - CLEAN AIR DUCT
    4 - AIR FILTER HOUSING ASSEMBLY
    5 - BOLT
    6 - VENT TUBE
  11. Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor and the Electronic Throttle Control (ETC).
  12. Install the throttle body air inlet hose and the air cleaner housing assembly. See Engine/Air Intake System/BODY, Air Cleaner - Installation .
  13. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
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