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Manifold, Intake: Installation: Upper

Fig 1: Upper Intake Manifold Brackets & Bolts
GC0154012Courtesy of CHRYSLER GROUP, LLC
  1. If removed, install the throttle body to the upper intake manifold. Refer to THROTTLE BODY, INSTALLATION .
  2. If removed, install the Manifold Air Pressure (MAP) sensor to the upper intake manifold. Refer to SENSOR, MANIFOLD AIR PRESSURE (MAP), INSTALLATION .
  3. If removed, install the brackets (1) to the upper intake manifold with bolts (2) tightened to 8 N.m (71 in. lbs.).
    Fig 2: Rear Insulation Pad & Push-Pins
    GC0154011Courtesy of CHRYSLER GROUP, LLC
  4. If removed, install the rear insulation pad (1) with push-pins (2) to the upper intake manifold.
    Fig 3: Identifying Fuel Rail Bolt Tightening Sequence
    GC0147420Courtesy 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 4: Intake Ports, Insulator & Alignment Posts
    GC0144184Courtesy of CHRYSLER GROUP, LLC
  5. 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.

  6. If removed, install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
    Fig 5: Upper Intake Manifold & Bolts
    GC0154021Courtesy of CHRYSLER GROUP, LLC
  7. 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.
  8. 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 6: Upper Intake Manifold Tightening Sequence
    GC0154022Courtesy of CHRYSLER GROUP, LLC
  9. Install the seven upper intake manifold attaching bolts. Tighten the bolts in the sequence shown in illustration to 10 N.m (89 in. lbs.).
    Fig 7: Right Upper Intake Manifold Support Bracket & Fasteners
    GC0154020Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Heater core coolant tube assembly not shown in illustration for clarity.

  10. Install the right upper intake manifold support bracket (1) with two bolts (2) tightened to 8 N.m (71 in. lbs.).
  11. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  12. Install two nuts (3) to the right upper intake manifold support bracket (1) and tighten to 10 N.m (89 in. lbs.).
  13. Install the right front wheelhouse inner splash shield. Refer to SHIELD, SPLASH, WHEELHOUSE, INSTALLATION .
    Fig 8: Transfer Case Vent Hose, Fresh Air Makeup Hose, Positive Crankcase Ventilation (PCV) Hose, Retainers & Fasteners
    GC0154019Courtesy of CHRYSLER GROUP, LLC
  14. Lower the vehicle.
  15. Install the heater core coolant tube assembly with two nuts (7) tightened to 10 N.m (89 in. lbs.).
  16. Engage two purge tube retainers (6) to the right upper intake manifold support bracket.
  17. Engage the wire harness retainer (1) to the upper intake manifold.
  18. Engage the wire harness connector retainer (2) to the right upper intake manifold support bracket.
  19. Engage the following hoses to the upper intake manifold:
    • Fresh air makeup (4)
    • Positive Crankcase Ventilation (PCV) (5)
    • Transfer case vent (3)
    Fig 9: Left Rear Upper Intake Manifold Support Bracket & Fasteners
    GC0154018Courtesy of CHRYSLER GROUP, LLC
  20. Install the left rear upper intake manifold support bracket (1) with two nuts (2) tightened to 10 N.m (89 in. lbs.).
  21. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  22. Install two studbolts (3) to the left rear upper intake manifold support bracket (1) and tighten to 20 N.m (177 in. lbs.).
  23. Install the left front wheelhouse inner splash shield. Refer to SHIELD, SPLASH, WHEELHOUSE, INSTALLATION .
    Fig 10: Brake Booster Hose Retainer & Wire Harness Retainers
    GC0154017Courtesy of CHRYSLER GROUP, LLC
  24. Lower the vehicle.
  25. Position the wire harness and engage the wire harness retainers (2) to the left rear upper intake manifold support bracket.
  26. Engage the brake booster hose retainer (1) to the left rear upper intake manifold support bracket.
    Fig 11: Left Front Upper Intake Manifold Support Bracket & Fasteners
    GC0154016Courtesy of CHRYSLER GROUP, LLC
  27. Install the left front upper intake manifold support bracket (1) with two nuts (2) and two bolts (3). Tighten the nuts (2) to 10 N.m (89 in. lbs.) and tighten the bolts (3) to 10 N.m (89 in. lbs.).
    Fig 12: Positive Crankcase Ventilation (PCV), Brake Booster & Vapor Purge
    GC0154015Courtesy of CHRYSLER GROUP, LLC
  28. Connect the following hoses to the upper intake manifold:
    • Positive Crankcase Ventilation (PCV) (1)
    • Vapor purge (3)
    • Brake booster (2)
    Fig 13: Manifold Absolute Pressure (MAP) Sensor, Electronic Throttle Control (ETC), Clip & Retainers
    GC0154014Courtesy of CHRYSLER GROUP, LLC
  29. Position the wire harness and connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (6).
  30. Engage the ETC harness to the clip (5) on the throttle body.
  31. Engage the wire harness retainer (2) to the upper intake manifold.
  32. Engage the wire harness retainers (3 and 4) to the left front upper intake manifold support bracket.
    Fig 14: Air Cleaner Body, Fresh Air Makeup Hose, Electrical Connector, Clamp, Bolts & Retainers
    GC0154000Courtesy of CHRYSLER GROUP, LLC
  33. Install the air cleaner body (1). Refer to BODY, AIR CLEANER, INSTALLATION .
    Fig 15: Engine Cover
    GC0153999Courtesy of CHRYSLER GROUP, LLC
  34. Install the engine cover (1).
  35. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
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