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Manifold, Intake: Installation: Upper

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Fig 1: Fuel Rail Bolt Tightening Sequence
GC0173652Courtesy of CHRYSLER GROUP, LLC
  1. 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
    GC0173670Courtesy of CHRYSLER GROUP, LLC
  2. Clean and inspect the sealing surfaces, the gaskets may be reused if no issues are found. Install the upper to lower intake manifold gaskets.
    GC0173757Courtesy of CHRYSLER GROUP, LLC
  3. 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.
    GC0173600Courtesy of CHRYSLER GROUP, LLC
  4. If removed, install the insulator (1) on top of the right cylinder head cover.
  5. 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 2: Upper Intake Manifold Bolt Tightening Sequence
    GC0173803Courtesy of CHRYSLER GROUP, LLC
  6. 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.
  7. Install the eight upper intake manifold attaching bolts. Tighten the bolts in the sequence shown to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0173737Courtesy of CHRYSLER GROUP, LLC
  8. Connect the brake vacuum booster hose (1) to the manifold.
    GC0173759Courtesy of CHRYSLER GROUP, LLC
  9. Install the two intake manifold support bracket upper bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0173706Courtesy of CHRYSLER GROUP, LLC
  10. Connect the EGR cooler hose (1) to the EGR valve.
  11. Connect the EGR valve wire harness connector.
    GC0173800Courtesy of CHRYSLER GROUP, LLC
  12. Install the EGR coolant tube to intake manifold nut (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0173624Courtesy of CHRYSLER GROUP, LLC
  13. Install the throttle body support bracket and tighten the nut (1) and bolt (2) to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0173622Courtesy of CHRYSLER GROUP, LLC
  14. Connect the Positive Crankcase Ventilation (PCV) hose (1) to the intake manifold.
    GC0173730Courtesy of CHRYSLER GROUP, LLC
  15. If removed, connect the evaporative purge solenoid hose (1) and evaporative purge solenoid (2) to the intake manifold.
    GC0173646Courtesy of CHRYSLER GROUP, LLC
  16. Connect the vapor purge line (1) to the solenoid.
    GC0173617Courtesy of CHRYSLER GROUP, LLC
  17. Connect the evaporative purge solenoid wire harness connector (1) and attach the wire harness (2) retainer to the manifold.
    GC0173616Courtesy of CHRYSLER GROUP, LLC
  18. Connect the front engine wire harness connectors (2) and attach the wire harness retainer (1) to the manifold.
  19. Install the air cleaner resonator. Refer to INSTALLATION 
  20. Connect the negative battery cable.
  21. Install the engine cover. Refer to COVER, ENGINE, INSTALLATION .
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