Installation - Lower Intake Manifold

Clean all gasket surfaces. Inspect gasket and replace as necessary.
Position new seals on lower intake manifold, if replaced (Fig 1).

Fig 1: Installing Lower Intake Manifold Seals
Courtesy of DAIMLERCHRYSLER CORP.
Install lower intake manifold. Tighten fasteners to 12 N.m (105 INCH lbs) in sequence shown in (Fig 2).

Fig 2: Identifying Lower Intake Manifold Tightening Sequence
Courtesy of DAIMLERCHRYSLER CORP.
If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 N.m (200 INCH lbs).
Connect fuel injector wiring harness.
Inspect quick connect fittings for damage, replace if necessary (Refer to FUEL LINE DISCONNECT FITTINGS ). Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
Install the screw attaching the oil dipstick tube to lower intake manifold (Figure).
Install coolant outlet connector and thermostat (Refer to ENGINE COOLANT THERMOSTAT ).
Install radiator upper hose.
Install upper intake manifold (Refer to INSTALLATION - UPPER INTAKE MANIFOLD ).
Connect negative cable to battery.
Install air cleaner housing and clean air hose.
Connect inlet air temperature sensor and make-up air hose.
Fill the cooling system (Refer to STANDARD PROCEDURE - FILLING COOLING SYSTEM ).
With the DRBIII® scan tool use ASD Fuel System Test to pressurize 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.