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Manifold, Intake: Installation: Upper

WARNING: This page is about a different variant/trim than selected.
Fig 1: Fuel Rail Bolt Tightening Sequence
GC0144261Courtesy 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
  1. 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.

  2. If removed, position the insulator (2) onto the two alignment posts (3) on top of the left cylinder head cover.
    Fig 3: Upper Intake Attaching Bolts, Locating Posts & Holes
    GC0144354Courtesy of CHRYSLER GROUP, LLC
  3. 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.
  4. 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 Bolt Tightening Sequence
    GC0144185Courtesy of CHRYSLER GROUP, LLC
  5. 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: Upper Intake Manifold Support Bracket, Stud & Fasteners
    GC0144428Courtesy of CHRYSLER GROUP, LLC
  6. Install two nuts (1) to the upper intake manifold support bracket (2). Tighten the nuts (1) to 10 N.m (89 in. lbs.) and tighten the stud (3) to 20 N.m (15 ft. lbs.)
  7. Engage the wire harness retainer (4) to the stud (3).
    Fig 6: Nuts, Stud Retainers & Upper Intake Manifold Support Brackets
    GC0144182Courtesy of CHRYSLER GROUP, LLC
  8. Install the two upper intake manifold support brackets (2) with two stud retainers (3) and two nuts (1). Tighten the stud retainers (3) to 20 N.m (15 ft. lbs.) and tighten the nuts (1) to 10 N.m (89 in. lbs.).
    Fig 7: Heater Core Return Tube Upper Support Bracket Retaining Nut & Tube
    GC0144665Courtesy of CHRYSLER GROUP, LLC
  9. Position the heater core return tube (1), install the retaining nut (2) and tighten to 12 N.m (9 ft. lbs.).
    Fig 8: MAP Sensor, ETC, PCV Hose, Brake Booster Vacuum Hose, EVAP Vapor Purge Line, Clip & Wire Harness Retainer
    GC0144427Courtesy of CHRYSLER GROUP, LLC
  10. Connect the following hoses to the upper intake manifold:
    • Positive Crankcase Ventilation (PCV) (7)
    • Brake booster vacuum hose (6)
    • EVAP vapor purge line (3)
  11. Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (2) and the Electronic Throttle Control (ETC) (4).
  12. Secure the ETC harness to the clip (5) on the throttle body and fasten the wire harness retainer (1) to the upper intake manifold near the MAP sensor.
    Fig 9: Brake Booster Hose Retainer
    GC0144507Courtesy of CHRYSLER GROUP, LLC
  13. Fasten the brake booster vacuum hose retainer (1) to the upper intake manifold.
    Fig 10: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose Assembly & Fasteners
    GC0144029Courtesy of CHRYSLER GROUP, LLC
  14. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
  15. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
  16. Tighten the clamp at the air cleaner housing (3) to 5 N.m (44 in. lbs.).
  17. Tighten the clamp (2) at the throttle body to 5 N.m (44 in. lbs.).
  18. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).
    Fig 11: Engine Cover
    GC0144028Courtesy of CHRYSLER GROUP, LLC
  19. Position the engine cover (1) and secure the retaining grommets onto the ball studs.
    Fig 12: Negative Battery Cable
    GC0139402Courtesy of CHRYSLER GROUP, LLC
  20. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  21. Start the engine and check for leaks.
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