C. Intake Manifold Installation

1. Using a shop vacuum, clean out any debris from the cylinder head intake ports.





2. Insert small pieces of paper shop towel into each of the intake ports to prevent dirt and debris from entering the intake ports while cleaning the cylinder head sealing surface (Figure 11).

3. Clean the intake manifold sealing surface on the cylinder head (Figure 11).

4. Carefully remove the paper shop towel installed in each of the intake ports (Figure 11).

5. Using a shop vacuum again, vacuum out any debris from the intake ports on the cylinder head.

6. Temporarily install the intake manifold gasket retaining studs shown in Figure 11.

7. Install the intake manifold gasket onto the cylinder head.

NOTE:
The studs will keep the intake manifold gasket in position during intake manifold installation.





8. Transfer the fuel pressure sensor to the new intake manifold (Figure 12).

9. Transfer the heater hose and plastic tube to the new intake manifold (Figure 12).

10. Install the new intake manifold onto the engine.

11. Hand start all intake manifold retaining bolts except for where the intake manifold gasket retaining studs are located.

12. Remove the two intake manifold gasket retaining studs.

13. Install the two remaining intake manifold retaining bolts in the two positions the studs were removed.

14. Tighten all intake manifold retaining bolts. Start tightening bolts from the center of the manifold and work outwards. Tighten the bolts to 142 in.lbs. (16 N.m).

15. Install the engine wiring harness using the following procedure:

a. Install the engine wiring harness into position on the engine.

NOTE:
The wiring harness routes between the second and third intake runners on the intake manifold.

b. Using Special Tool 9286, connect the five glow plug electrical connectors onto the glow plugs (Figure 6).

c. Connect the engine harness retaining bolt.

d. Connect the electrical connectors at the five fuel injectors (Figure 6).

e. Connect the ABS module connectors located under the battery.

f. Connect all electrical connectors that are related to the engine harness.

g. Tie straps the engine wiring harness to the main wiring harness.

h. Feed the three engine wiring harness connectors through the dash panel opening in the dash panel and seat the rubber grommet (Figure 5).

i. Connect the three engine electrical harness connectors located under the instrument panel.

16. Install the lower intake manifold support bracket.

17. Connect the heater hose at the lower intake manifold support bracket.

18. Connect the fuel tube to the fuel pressure sensor located on the bottom side of the intake manifold (Figure 12).

19. Install the fuel filter and bracket assembly onto the frame.

20. Install the center fuel tube at the fuel filter (Figure 3).

21. Connect the inboard fuel hose at the fuel filter (Figure 3).

22. Install the steel high pressure pump-to-fuel rail tube (Figure 4). Tighten the tube nuts to 195 in. lbs. (22 N.m).

23. Using Special Tool 9285, install the five injector rail-to-injector crossover tubes (Figure 2). Tighten the tubes to 195 in. lbs. (22 N.m).

24. Install the upper radiator hose.

25. Install the brake booster vacuum hose (Figure 2).

26. Install the radiator coolant recovery bottle hose.

27. Install the two bolts for the rear aluminum intake manifold support bracket (Figure 2).

28. Install the intake manifold upper steel support bracket (Figure 2).

29. Inspect the EGR mixing chamber for excessive carbon build-up. Clean EGR mixing chamber, if required, using Mopar Throttle Body Cleaner (P/N 04897156AB).

30. Install the Exhaust Gas Recirculation (EGR) mixing chamber onto the intake manifold (Figure 1). Tighten the EGR mixing chamber bolts to 124 in. lbs. (14 N.m).

31. Install the intake manifold charge air hose (Figure 1).

32. Fill the engine cooling system with coolant.

33. Connect the negative battery cable.

34. Start the engine and visually inspect for fuel leaks.

CAUTION:
It may take several seconds of engine cranking, several times, before the engine will start. This is due to air in the fuel tubes. Use care not to overheat the starter during the starting process.

35. Install the engine fuel injector cover onto the engine (Figure 1).