Installation

INSTALLATION

1. Clean manifold sealing surfaces.
2. Install new intake manifold gasket.
3. Install upper intake manifold and tighten fasteners to 31 Nm (275 in. lbs.) in sequence shown in (Figure 1). Repeat this procedures until all fasteners are at specified torque.




Figure 1 Upper Intake Manifold Tightening Sequence - 2.4L


NOTE: Failure to follow intake manifold support bracket torque sequence could result in a leak or damage to intake manifold.

4. Install engine oil dipstick.
5. Install upper bolt (2) hand tight in intake manifold to front support bracket. Install lower intake manifold support nut (1) and torque to 28 Nm (250 in. lbs.).
6. Torque upper intake manifold support bracket bolt (2) to 28 Nm (250 in. lbs.).




Figure 2 Upper Intake Manifold Support Bracket






7. Install EGR tube.
8. Install throttle cables in bracket.
9. Connect throttle and speed control (if equipped) cables to throttle lever.
10. Connect vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold fittings.
11. Connect vacuum lines for purge solenoid and PCV valve.
12. Connect electrical connectors for MAP sensor, throttle position sensor (TPS), and idle air control (IAC) motor.
13. Install air cleaner upper housing and air intake tube to throttle body.
14. Connect inlet air temperature sensor connector (Figure 3).
15. Connect negative cable to battery.





Figure 3 Inlet Air Temperature Sensor - 2.4L