Installation

INSTALLATION - UPPER INTAKE MANIFOLD

1. If the following components were removed from manifold, install and tighten to specifications:

CAUTION: The special screws used for the composite manifold attached components must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available.

- MAP sensor - 1.7 Nm (15 in. lbs.)
- Throttle cable bracket - 5.6 Nm (50 in. lbs.)
2. Remove covering on lower intake manifold and clean surfaces.
3. Inspect manifold gasket condition. Gaskets can be re-used, if not damaged. To replace, remove gasket from upper manifold (Figure 5). Position new gasket in seal channel and press lightly in-place. Repeat procedure for each gasket position.
4. Position upper manifold on lower manifold (Figure 5). Apply Mopar(R) Lock & Seal Adhesive (Medium Strength Threadlocker) to each upper intake manifold bolt. Install and tighten bolts to 12 Nm (105 in. lbs.) following torque sequence in (Figure 1).




Figure 1 UPPER MANIFOLD TIGHTENING SEQUENCE

5. Connect the MAP sensor electrical connector.
6. Connect the brake booster and LDP vacuum hose to intake manifold (Figure 4).

CAUTION: The special screws used for attaching the EGR tube and power steering reservoir to the manifold must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available..

7. Install the power steering reservoir (Figure 3). Tighten screws to manifold to 5.6 Nm (50 in. lbs.).
8. Connect throttle and speed control cables to throttle body
9. Attach make up air hose clip into the hole in the throttle cable bracket.
10. Connect the wiring connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS) motor.




Figure 2 PCV HOSE







NOTE: PCV valve MUST be seated into the right cylinder head cover. The PCV valve hose MUST cover the right cylinder head cover, PCV housing completely. Failure to do so may cause higher idle and emission faults.

11. Install PCV hose (Figure 2).
12. Install air cleaner and air inlet hose assembly.
13. Connect the inlet air temperature (IAT) sensor electrical connector.
14. Connect battery negative cable.





Figure 3 POWER STEERING FLUID RESERVOIR











Figure 4 BRAKE BOOSTER & LDP VACUUM HOSES











Figure 5 INTAKE MANIFOLD - UPPER