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Installation - Upper

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean manifold sealing surfaces.
  2. Apply a 1.5 mm (0.060 in.) bead Mopar® Gasket Maker to the perimeter of the lower intake manifold runner openings.
  3. Install upper intake manifold and tighten fasteners to 28 N.m (250 in. lbs.) in sequence shown in Fig 1. Repeat this procedures until all fasteners are at specified torque.
    Fig 1: Upper Intake Manifold Tightening Sequence - 2.4L
    GC0026088Courtesy of DAIMLERCHRYSLER CORP.
  4. Install engine oil dipstick.
  5. Install upper bolt in intake manifold to front support bracket.
  6. Install EGR tube.
  7. Install throttle cables in bracket.
  8. Connect throttle, speed control, (if equipped), cables to throttle lever.
  9. Connect vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold fittings.
  10. Connect vacuum lines for purge solenoid and PCV valve.
  11. Connect electrical connectors for MAP sensor, throttle position sensor (TPS), and idle air control (IAC) motor.
  12. Install air cleaner upper housing and air intake tube to throttle body.
  13. Connect inlet air temperature sensor connector.
  14. Connect negative cable to battery.
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