Manifold, Intake: Installation: Installation

WARNING: This page is about a different car, the 2016 RAM 3500 HD and 2016 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Inspect seal conditions. Seals can be reused, if not damaged. Position seal in the seal channel and press lightly into place. Repeat procedure for each seal position.

Fig 1: Intake Manifold & PCV Seals

Courtesy of CHRYSLER GROUP, LLC

NOTE:

If reinstalling the original manifold apply Mopar® Lock & Seal Adhesive to the intake manifold bolts. Not required when installing a new manifold.

Apply Mopar® Lock & Seal Adhesive to the intake manifold bolts.
Install the intake manifold seals (3) and positive crankcase ventilation (PCV) seals (1).

Fig 2: Intake Manifold Removal/Installation Sequence
Courtesy of CHRYSLER GROUP, LLC
Using the sequence shown in illustration, tighten the intake manifold bolts to 12 N.m (9 ft. lbs.).
Position the main engine electrical harness at the rear of the intake manifold and install the support strap.
Connect the fuel supply line quick connect fitting at the fuel rail (1).
NOTE:
The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the harness was not tagged, use the noted the electrical connector's location during removal.

Fig 3: Fuel Injector Electrical Connectors
Courtesy of CHRYSLER GROUP, LLC
Position the fuel injector electrical harness and connect the electrical connectors (1) to all fuel injectors.

Fig 4: MAP Sensor
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Connect the map sensor electrical connector (1).

Fig 5: Removing/Installing EGR Crossover Tube
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Install the EGR crossover tube (2). Tighten bolts (1) to 24 N.m (18 ft. lbs.).

Fig 6: Generator, Bolts & Connector
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Install the generator (1). Torque the bolts to 50 N.m (37 ft. lbs.).

Fig 7: Separating A/C Line Support Bracket
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Position the A/C line Bracket (2) to the manifold. Torque the bolt (1) to 50 N.m (37 ft. lbs.).

Fig 8: Throttle Body, Throttle Body Mounting Bolts & Electrical Connector
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Position the wiring harness (2) and connect the electrical connector at the throttle body (1).
NOTE:
While installing the engine cover the front ball studs will make a popping or suction sound as the ball studs are inserted into the front grommets.

Fig 9: Engine Cover & Grommets
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Lower the front of the engine cover (1) and line up the front grommets (2) with the ball studs on the front of the intake manifold and with a downward motion push the engine cover front grommets onto the ball studs.
NOTE:
Lightly lift the front of the engine cover to insure the front ball studs are seated into the front grommets correctly.

Fig 10: Clamp, Air Intake Tube & Breather Hose
Courtesy of CHRYSLER GROUP, LLC
Connect the intake air tube to the air cleaner assembly and the throttle body.
Connect the breather air hose (3).

Fig 11: Temperature Sensors, Mass Air Flow (MAF) Sensor (1), Intake Air Temperature (IAT) Sensor (2) Component Location
Courtesy of CHRYSLER GROUP, LLC
Connect the temperature sensor (2).

Fig 12: Battery
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Connect the negative battery cable (1).