Lower

INSTALLATION

1. Place a bead (approximately 1/4 in. diameter) of Mopar(R) Engine RTV GEN II onto each of the four manifold to cylinder head gasket corners (1).

2. Carefully install the new intake manifold gasket (3). Tighten the end seal retainer bolts (2) to 12 Nm (105 in. lbs.).
3. Position the lower intake manifold (1) on the gasket (3).

4. Install the injector harness connector support bracket (2) and bolt (1). The bolt will be tightened in the next step.

5. Install the rest of the intake manifold bolts. Initially tighten all bolts to 1 Nm (10 in lbs.). Finish tightening the bolts in two steps, first to 22 Nm (200 in. lbs.) in the sequence shown, then again to 22 Nm (200 in. lbs.) in the sequence shown. After the intake manifold is in place, inspect to make sure seals are in place.

6. Install the front cover support bracket (3) with two bolts (1) and nut (2). Tighten the nut to 22 Nm (200 in. lbs.). Tighten the bolts to 25 Nm (18 ft. lbs.).
7. Install the upper radiator hose.

8. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each of the injectors.

9. Insert the fuel injector nozzles into the openings in the lower intake manifold. Seat the injectors in place. Install the fuel rail bolts and tighten bolts to 12 Nm (106 in. lbs.).

10. Correctly position and connect the fuel injector electrical harness connectors to the fuel injectors.
11. Connect the fuel injector electrical harness connectors (1) and (2).

12. Connect the heater supply hose and the Engine Coolant Temperature (ECT) sensor electrical connector (2).

13. Install the ignition coil (5) and bracket (6).

14. Connect the fuel supply hose to the fuel rail.

15. Install the upper intake manifold (4) and EGR tube Intake Manifold - Installation.
16. Fill the cooling system Service and Repair
17. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
18. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.