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Manifold, Intake: Installation: Upper

WARNING: This page is about a different car, the 2013 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removed, install the throttle body to the upper intake manifold. Refer to THROTTLE BODY, INSTALLATION .
  2. If removed, install the Manifold Air Pressure (MAP) sensor to the upper intake manifold. Refer to SENSOR, MANIFOLD AIR PRESSURE (MAP), INSTALLATION .
  3. If removed, install the brackets (1) to the upper intake manifold with bolts (2) tightened to 8 N.m (71 in. lbs.).
  4. If removed, install the rear insulation pad (1) with push-pins (2) to the upper intake manifold.
    Fig 1: Fuel Rail Bolt Tightening Sequence
    GC0147420Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Prior to installing the upper intake manifold, verify that the four fuel rail bolts were not inadvertently loosened. The bolts must tightened in the sequence shown in illustration to 7 N.m (62 in. lbs.). Refer to RAIL, FUEL, INSTALLATION .

    Fig 2: Intake Ports, Insulator & Alignment Posts
    GC0144184Courtesy of CHRYSLER GROUP, LLC
  5. Clean and inspect the sealing surfaces. Install new upper to lower intake manifold seals (1).
    NOTE:

    Make sure the fuel injectors and wiring harnesses are in the correct position so that they don't interfere with the upper intake manifold installation.

  6. If removed, install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
    Fig 3: Upper Intake Manifold & Bolts
    GC0154021Courtesy of CHRYSLER GROUP, LLC
  7. Lift and hold the seven upper intake attaching bolts (1) clear of the mating surface. Back the bolts out slightly or if required, use an elastic band to hold the bolts clear of the mating surface.
  8. Position the upper intake manifold (1) onto the lower intake manifold so that the two locating posts (2) on the upper intake manifold align with corresponding holes (3) in the lower intake manifold.
    Fig 4: Upper Intake Manifold Tightening Sequence
    GC0154022Courtesy of CHRYSLER GROUP, LLC
  9. Install the seven upper intake manifold attaching bolts. Tighten the bolts in the sequence shown in illustration to 8 N.m (71 in. lbs.).
    Fig 5: Transfer Case Vent Hose, Fresh Air Makeup Hose, Positive Crankcase Ventilation (PCV) Hose, Retainers & Fasteners
    GC0154019Courtesy of CHRYSLER GROUP, LLC
  10. Engage the wire harness retainer (1) to the upper intake manifold.
  11. Engage the wire harness connector retainer (2) to the right upper intake manifold support bracket.
  12. Engage the following hoses to the upper intake manifold:
    • Fresh air makeup (4)
    • Positive Crankcase Ventilation (PCV) (5)
    • Transfer case vent (3)
    Fig 6: Left Rear Upper Intake Manifold Support Bracket And Fasteners
    GC0154592Courtesy of CHRYSLER GROUP, LLC
  13. Install the left rear upper intake manifold support bracket (1) with two nuts (2) tightened to 10 N.m (89 in. lbs.).
  14. Tighten the two studbolts (3) to the left rear upper intake manifold support bracket (1) to 20 N.m (177 in. lbs.).
    Fig 7: Brake Booster Hose Retainer & Wire Harness Retainers
    GC0154017Courtesy of CHRYSLER GROUP, LLC
  15. Position the wire harness and engage the wire harness retainers (2) to the left rear upper intake manifold support bracket.
  16. Engage the brake booster hose retainer (1) to the left rear upper intake manifold support bracket.
    Fig 8: Left Front Upper Intake Manifold Support Bracket & Fasteners
    GC0154016Courtesy of CHRYSLER GROUP, LLC
  17. Install the left front upper intake manifold support bracket (1) with two nuts (2) and two bolts (3). Tighten the nuts (2) to 10 N.m (89 in. lbs.) and tighten the bolts (3) to 10 N.m (89 in. lbs.).
    Fig 9: Positive Crankcase Ventilation (PCV), Brake Booster & Vapor Purge
    GC0154015Courtesy of CHRYSLER GROUP, LLC
  18. Connect the following hoses to the upper intake manifold:
    • Positive Crankcase Ventilation (PCV) (1)
    • Vapor purge (3)
    • Brake booster (2)
    Fig 10: Manifold Absolute Pressure (MAP) Sensor, Electronic Throttle Control (ETC), Clip & Retainers
    GC0154014Courtesy of CHRYSLER GROUP, LLC
  19. Position the wire harness and connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (6).
  20. Engage the ETC harness to the clip (5) on the throttle body.
  21. Engage the wire harness retainer (2) to the upper intake manifold.
  22. Engage the wire harness retainers (3 and 4) to the left front upper intake manifold support bracket.
    Fig 11: IAT Sensor Electrical Connector
    GC0154633Courtesy of CHRYSLER GROUP, LLC
  23. Install the air intake resonator to the throttle body. Hand tighten the clamp.
  24. Connect the IAT sensor electrical connector (2).
    Fig 12: Breather Tube & Resonator
    GC0154529Courtesy of CHRYSLER GROUP, LLC
  25. Install the breather hose (1) to the air intake resonator (2).
    Fig 13: Removing/Installing Air Filter Box Cover
    GC0154523Courtesy of CHRYSLER GROUP, LLC
  26. Install the air intake hose (1) to the resonator.
  27. Install the air cleaner cover (2).
  28. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
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