Manifold, Intake: Installation: Installation

WARNING: This page is about a different car, the 2014 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Intake Manifold & Gaskets

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Clean the gasket sealing surfaces. Refer to ENGINE GASKET SURFACE PREPARATION .
Install a new intake manifold gasket (1, 3).

Fig 2: Intake Manifold & Bolts
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Install the intake manifold and tighten bolts finger tight.

Fig 3: Intake Manifold Tightening Sequence
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Fig 4: Intake Manifold Tightening Sequence
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Using the tightening sequence shown in illustration, tighten bolts to 12 N.m (106 in. lbs.).

Fig 5: Right & Left High Pressure Fuel Tubes & Union Nuts
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NOTE:
Fuel tubes are a one time only use and must be replaced anytime they have been removed.
Install the left side fuel rail. Refer to RAIL, FUEL, INSTALLATION .
Attach the fuel injector return line to the top of intake manifold.
Install the new left high pressure fuel tube (11) and tighten union nuts (10, 12) finger tight:
- Tighten union nut (10) to 5 N.m (44 in. lbs.) plus an additional 75 degrees turn.
- Tighten union nut (12) to 11 N.m (97 in. lbs.) plus an additional 75 degrees turn.
Fig 6: High Pressure Pump Blocker Shield & Bolts
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Install the high pressure pump blocker shield. Tighten bolts to 25 N.m (18 ft. lbs.).

Fig 7: EGR Air Flow Control Valve & Bolt
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Position and properly route and install the engine wiring harness.
Attach the vacuum brake booster tube to the top of intake manifold.
Connect the EGR solenoid vacuum lines.
Install the EGR air flow control valve (2). Refer to VALVE, EXHAUST GAS RECIRCULATION (EGR) AIRFLOW CONTROL, INSTALLATION .

Fig 8: Turbocharger Outlet Flange & O-Ring
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Install a new O-ring seal (1) onto turbocharger outlet flange (2).

Fig 9: Turbocharger Outlet Elbow & Bolts
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Install the turbocharger outlet elbow (1). Tighten bolts (2) to 10 N.m (89 in. lbs.).

Fig 10: Air Outlet Temperature Sensor
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Connect the turbocharger outlet temperature sensor wire harness connector (1).

Fig 11: Fuel Rail Cross-Over Line & Bolt
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Install the EGR tube. Refer to TUBE, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
Install a new fuel cross over line (1). Tighten the bolt (2) to 11 N.m (97 in. lbs.).

Fig 12: Wiring Harness Connectors & Fasteners
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Install the wiring loom (2) to the intake manifold. Tighten the Ball stud (2) and the bolt (6) to 11 N.m (97 in. lbs.).

Fig 13: CAC Hose & EGR Air Flow Control Valve
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Connect the CAC hose (1) to the EGR air flow control valve.

Fig 14: Remove/Install Fuel Injector Return Line
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Install the fuel manifold (4). Tighten nut (3) to 8 N.m (71 in. lbs.).

Fig 15: Removing/Installing Intake Manifold Silencer
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Install the CAC hose from turbocharger to resonator.
Install the Install the intake manifold silencer (2).

Fig 16: Remove/Install Air Cleaner Body & Intake Air Tube
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Install the air cleaner body and intake air tube. Refer to BODY, AIR CLEANER, INSTALLATION .

Fig 17: Removing/Installing Engine Cover
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Install the engine cover (1).
Connect the negative battery cable.
Start the engine, allow to warm, turn the engine off and inspect for leaks.