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Lower Intake Manifold

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Fig 1: LOWER INTAKE MANIFOLD TIGHTENING SEQUENCE
GC0015454Courtesy of DAIMLERCHRYSLER CORP.
  1. Clean all sealing surfaces.
  2. Position new gaskets and intake manifold on cylinder head surfaces.
  3. Install intake manifold bolts and gradually tighten in sequence shown. See Fig 1 until a torque of 28 N.m (250 in. lbs.) is obtained.
    Fig 2: FUEL RAIL AND LOWER INTAKE MANIFOLD
    GC0015453Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL RAIL
    2 - IGNITION COIL
    3 - LOWER INTAKE MANIFOLD
    4 - PCV VALVE
  4. Install fuel rail and injectors as an assembly. See Fig 2, (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION) .
  5. Connect fuel supply hose to fuel rail. (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - STANDARD PROCEDURE)
    Fig 3: COOLANT PIPE
    GC0015399Courtesy of DAIMLERCHRYSLER CORP.
    1 - COOLANT PIPE
    2 - HEATER HOSE
    3 - COOLANT RESERVOIR HOSE
  6. Connect heater hose to rear lower intake manifold. See Fig 3.
  7. Connect coolant container hose to the rear lower intake manifold. See Fig 3.
  8. Connect electrical connectors to fuel injectors and coolant temperature sensor.
  9. Install power steering fluid reservoir and bracket.
  10. Install upper intake manifold (Refer to MANIFOLD - INTAKE ).
  11. Connect the upper radiator hose to the thermostat housing.
  12. Fill the cooling system (Refer to STANDARD PROCEDURE ).
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