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Cylinder Head Cover/Intake Manifold Tightening Procedure

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. Alternate between bolts #11 and #16 to seat cylinder head cover/intake manifold on cylinder head. See Figure. Torque bolts to 7 N.m.
  2. Torque all cylinder head cover/intake manifold retaining bolts to 25 N.m in numerical order starting with #1 and ending with #16. See Figure.
Fig 1: EGR AIR CONTROL VALVE
GC0026154Courtesy of DAIMLERCHRYSLER CORP.
1 - OIL LEVEL INDICATOR
2 - RETURN FUEL JUNCTION BLOCK
3 - RETURN FUEL FROM HIGH PRESSURE PUMP
4 - EGR VALVE
5 - EGR TUBE FROM EGR COOLER
6 - EGR AIR CONTROL VALVE
7 - BRAKE BOOSTER VACUUM TUBE
8 - FUEL RAIL
  1. Connect the fuel return junction block to the intake manifold/cylinder head cover. See Fig 1.
  2. Install the oil separator and outlet hose (Refer to ENGINE/LUBRICATION/OIL - INSTALLATION) .
  3. Install the fuel rail (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - INSTALLATION) .
  4. Install fuel injectors and fuel injector supply lines (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION) .
  5. Connect EGR tube at EGR air control valve. Torque clamp to 10.8 N.m. See Fig 1.
  6. Install oil level indicator tube retaining bolt at intake manifold inlet. Torque bolt to 10 N.m (88 in. lbs.). See Fig 1.
  7. Install brake booster vacuum tube retaining bolt at intake manifold inlet. Torque bolt to 10 N.m (88 in. lbs.). See Fig 1.
  8. Install inner timing belt cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION) .
  9. Install timing belt (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) .
  10. Install outer timing belt cover (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN COVER(S) - INSTALLATION) .
  11. Remove both camshaft locking pins (VM.1052, VM1053) and install plugs. (Refer to ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  12. Install vibration damper (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) .
  13. Install the power steering pump pulley.
  14. Install the accessory drive belt tensioner
  15. Install the accessory drive belt pulleys L.H.Thread. 
  16. Install generator (Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
  17. Install cooling fan support (Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
  18. Install accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
  19. Position heater hose pipe to intake manifold/cylinder head cover and install fasteners.
  20. Position main engine wiring harness over the engine and connect the harness connectors at the right inner fender well.
  21. Connect camshaft position sensor, boost pressure/intake air temperature sensor, EGR solenoid, and fuel rail and pressure sensor electrical connectors.
  22. Install cooling fan, fan drive viscous clutch assembly and fan shroud. Refer to RADIATOR - FAN - VISCOUS .
  23. Route and connect the A/C hoses to fan shroud.
  24. Connect the radiator and charge air hoses.
  25. Connect the coolant recovery container hose to radiator.
  26. Refill cooling system. Refer to STANDARD PROCEDURE .
  27. Install the air cleaner housing.
  28. Install engine cover and bracke. Refer to ENGINE COVER .
  29. Recharge A/C.
  30. Connect negative battery cable.
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