MANIFOLD, Intake: Installation: Installation

Fig 1: Intake Manifold Bolt Removal & Tightening Sequence

Courtesy of CHRYSLER LLC

1. Clean all gasket surfaces.
2. Replace intake manifold gasket.
3. Install intake manifold, tighten bolts to 25 N.m (220 in. lbs.).
   Fig 2: Radiator Hose Support

   Courtesy of CHRYSLER LLC
4. Install the upper radiator hose retaining bracket (1).
   Fig 3: Throttle Body Support

   Courtesy of CHRYSLER LLC
5. Install the throttle body support bracket (1).
6. Connect the electronic throttle control electrical connector.
7. Install the wiring harness retainer to the intake manifold (2).
8. Connect the MAP sensor electrical connector.
9. Connect the vacuum lines to the intake manifold.
   Fig 4: Oil Temperature Sensor

   Courtesy of CHRYSLER LLC
10. Connect the oil temperature sensor (1).
11. Connect the variable valve timing solenoid electrical connector.
12. Connect the intake camshaft position sensor electrical connector.
    Fig 5: Coil Connectors

    Courtesy of CHRYSLER LLC
13. Install the fuel rail assembly to intake manifold. Tighten bolts to 23 N.m (200 in. lbs.).
14. Connect fuel injector electrical connectors (4).
15. Inspect quick connect fittings for damage, replace if necessary. Refer to STANDARD PROCEDURE - QUICK-CONNECT FITTINGS . Connect fuel supply hose (3) to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
    Fig 6: Air Cleaner Body, Air Inlet Tube & Make-Up Air Hose

    Courtesy of CHRYSLER LLC
16. Push down on the air cleaner body (1) to engage the pins into the grommets.
17. Install the support bracket bolt to the strut tower and tighten to 10 N.m (89 in. lbs.).
18. Install the air inlet tube (2) to the air cleaner body (1).
19. Connect the make-up air hose (3) to the air cleaner body.
    Fig 7: Electrical Connectors, PCM, Three Mounting Bolts & Ground Wire

    Courtesy of CHRYSLER LLC
20. Install the mounting bolt (3) with ground wire (1) and tighten to 12 N.m (106 in. lbs.).
21. Connect and lock the electrical connectors (2).
    Fig 8: Retainers, Fresh Air Inlet Duct & Air Cleaner Body

    Courtesy of CHRYSLER LLC
22. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
23. Install the fresh air inlet duct (3) on the air cleaner body (1) and lock the retainers (2).
    Fig 9: Engine Cover - 2.4L

    Courtesy of CHRYSLER LLC
24. Install the engine cover (1).