Intake Manifold: Installation

CAUTION: When cleaning the intake manifold and cylinder head mating surfaces, do not use a metal scraper because the surfaces could be cut or ground. Instead, use a wooden or plastic scraper.

Remove covering from intake manifold openings and clean gasket surfaces.
Carefully install the intake manifold gaskets and alignment pins (Fig 1).

Fig 1: Installing Intake Manifold Gaskets
Courtesy of DAIMLERCHRYSLER CORP.
Connect ignition coil connectors.
Set the intake manifold in position on the engine. Install intake manifold bolts and tighten initially to 1 N.m (10 in. lbs.). Tighten bolts starting at the center and working outward to 11 N.m (95 in. lbs.).
Connect CCV hoses to left and right cylinder head covers.
Clip coolant bottle inlet hose to throttle body bracket (Figure).
Connect fuel line to fuel rail (Figure). Pull backward on the quick connect fitting to ensure complete insertion.
Reconnect the following electrical connectors:
- Oil Pressure Sensor
- Oil Temperature Sensor
- Generator Field (2 way)
- Inlet Air Temperature (IAT) Sensor
- Engine Coolant Temperature (ECT) Sensor
- Camshaft Position Sensor
- PCM Connectors
- Body Harness Connector (Left Frame Rail Area)
Connect brake booster vacuum hose and evaporative emission harness hoses.
Install throttle cable into bracket. Connect throttle cable to throttle cam (Figure).
Install air cleaner housing assembly, connect throttle body air inlet hose (Refer to AIR CLEANER HOUSING ).
Connect negative battery cable. Install battery cover. Close trunk lid.
With the DRB III® Scan Tool, use the ASD Fuel System Test to pressurize fuel system to check for leaks.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.