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Intake Manifold: Installation

  1. Clean the gasket surfaces of the cylinder heads and the intake manifold.
  2. Position the intake manifold (1) on the cylinder heads with new gaskets (2) in place.
    Fig 1: Installing Intake Manifold
    G01860683Courtesy of DAIMLERCHRYSLER CORP.
  3. Install the intake manifold bolts and tighten to 20 N.m (15 ft. lbs.).
  4. Install the air pump switchover valves (4). Tighten the bolts to 20 N.m (15 ft. lbs.).
  5. Connect the EGR pipe fitting (1) to the EGR valve (2). Tighten the EGR pipe fitting to 40 N.m (30 ft. lbs.).
    Fig 2: Connecting EGR Pipe Fitting To EGR Valve
    G01860684Courtesy of DAIMLERCHRYSLER CORP.
  6. Install the mass air flow sensor. See FUEL SYSTEM article.
  7. Connect the engine harness connectors.
  8. Connect the vacuum lines at the crankcase ventilator, purge valve, EGR valve, and the brake booster.
  9. Install the fuel rail with fuel injectors. See FUEL SYSTEM article.
  10. Install the air cleaner housing. See AIR CLEANER HOUSING .
  11. Connect the negative battery cable.
  12. Start the engine and check for leaks.
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