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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.
NOTE: Care must be taken to protect the intake manifold powder coat from possible scrapes and abrasions.
  1. Clean gasket surfaces and remove covering from intake manifold openings.
  2. Carefully install the intake manifold gaskets and alignment pins. See Fig 1.
    Fig 1: Intake Manifold Gaskets Installation
    GC0004092Courtesy of DAIMLERCHRYSLER CORP.
    1 - ALIGNMENT PINS
    2 - INTAKE MANIFOLD GASKET
  3. 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.). See Fig 2.
    Fig 2: Intake Manifold Tightening Sequence
    GC0004093Courtesy of DAIMLERCHRYSLER CORP.
  4. Connect CCV hoses to left and right cylinder head covers.
  5. Connect fuel line to fuel rail. See Figure. Pull backward on the quick connect fitting to ensure complete insertion.
  6. Connect the brake booster vacuum hose.
  7. Connect the throttle cable housing to the bracket and then attach the cable to the throttle linkage. See Figure.
  8. Clip coolant bottle inlet hose to throttle body bracket and attach the purge solenoid hose to the underside of the throttle body housing. See Figure.
  9. Reconnect the following electrical connectors:
    1. Left cylinder head fuel injectors
    2. Engine Coolant Temperature (ECT) Sensor
    3. MAP sensor
    4. Idle Speed Control
    5. Throttle Position Sensor
    6. Right cylinder head fuel injectors
  10. Install air cleaner housing assembly, connect throttle body air inlet hose and connect the Intake Air Temperature Sensor (Refer to AIR CLEANER HOUSING ).
  11. Install the wiper motor cowl screen
  12. Install the wiper arms.
  13. Connect negative battery cable. Install battery cover. Close trunk lid.
  14. 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.
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