Manifold, Intake: Installation: Upper

WARNING: This page is about a different car, the 2016 Dodge Durango. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Fuel Rail Bolts

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Prior to installing the upper intake manifold, verify that the four fuel rail bolts (1) were not inadvertently loosened. If loosened, the bolts must tightened in sequence. Refer to RAIL, FUEL, INSTALLATION .

Fig 2: Upper To Lower Intake Manifold Gaskets
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Clean and inspect the sealing surfaces, the gaskets may be reused if no issues are found. Install the upper to lower intake manifold gaskets.

Fig 3: Fuel Injector Wire Harness Connectors & Wire Harness
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Make sure the fuel injectors (1) and wiring harnesses (2) are in the correct position so that they don't interfere with the upper intake manifold installation.

Fig 4: Insulator
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If removed, install the insulator (1) on top of the right cylinder head cover.
Lift and hold the upper intake attaching bolts 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.

Fig 5: Upper Intake Manifold Bolts Tightening Sequence
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Position the upper intake manifold onto the lower intake manifold so that the locating posts on the upper intake manifold align with corresponding holes in the lower intake manifold.
Install the eight upper intake manifold attaching bolts. Tighten the bolts in the sequence shown in illustration to the proper specification. Refer to TORQUE SPECIFICATIONS .

Fig 6: Brake Booster Vacuum Hose
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Connect the brake vacuum booster hose (2) to the manifold (1).

Fig 7: Upper Intake Manifold Support Bracket Bolts
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Install the two upper intake manifold support bracket bolts (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .

Fig 8: EGR Cooler Hose Clamp
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Connect the EGR cooler hose (1) to the EGR valve.
Connect the EGR valve wire harness connector.

Fig 9: Coolant Tube Bracket Retaining Nut
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Install the coolant tube bracket onto the studs and tighten the retaining nut (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .

Fig 10: Front Support Bracket, Nut & Bolt
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Install the support bracket and tighten the nut (1) and bolt (2) to the proper specification. Refer to TORQUE SPECIFICATIONS .

Fig 11: PCV Hose & Retaining Clips
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Connect the Positive Crankcase Ventilation (PCV) hose (2) to the intake manifold (1).

Fig 12: Purge Solenoid Vacuum Hose & Purge Solenoid
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If removed, connect the evaporative purge solenoid hose (1) and evaporative purge solenoid (2) to the intake manifold.

Fig 13: Vapor Purge Line
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Connect the vapor purge line (1) to the solenoid.

Fig 14: Vapor Purge Line & Wire Harness Connector
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Connect the evaporative purge solenoid wire harness connector (1) and attach the wire harness retainer (2) to the manifold.

Fig 15: Wire Harness Retainer & Front Engine Wire Harness Connectors
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Connect the front engine wire harness connectors (2) and attach the wire harness retainer (1) to the manifold.
Install the air cleaner intake body. Refer to BODY, AIR CLEANER, INSTALLATION .
Connect the negative battery cable.
Install the engine cover. Refer to COVER, ENGINE, INSTALLATION .