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Manifold, Intake: Installation: Upper

WARNING: This page is about a different car, the 2020 Chrysler 300 and 2019 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Fuel Rail Bolt Tightening Sequence
GC0144261Courtesy of CHRYSLER GROUP, LLC
NOTE:

Prior to installing the upper intake manifold, verify that the four fuel rail bolts were not inadvertently loosened. The bolts must tightened in the sequence shown in illustration to the proper specification. Refer to TORQUE SPECIFICATIONS  .

GC0144184Courtesy of CHRYSLER GROUP, LLC
  1. Clean and inspect the sealing surfaces. Install new upper to lower intake manifold seals (1).
    NOTE:

    Make sure the fuel injectors and wiring harnesses are in the correct position so that they don't interfere with the upper intake manifold installation.

  2. If removed, position the insulator (2) onto the two alignment posts (3) on top of the left cylinder head cover.
    GC0144354Courtesy of CHRYSLER GROUP, LLC
  3. Lift and hold the seven upper intake attaching bolts (1) clear of the mating surface. Back the bolts out slightly or if required, use an elastic band to hold the bolts clear of the mating surface.
  4. Position the upper intake manifold (1) onto the lower intake manifold so that the two locating posts (2) on the upper intake manifold align with corresponding holes (3) in the lower intake manifold.
    Fig 2: Upper Intake Manifold Tightening Sequence
    GC0144185Courtesy of CHRYSLER GROUP, LLC
  5. Install the seven upper intake manifold attaching bolts. Tighten the bolts in the sequence shown in illustration to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0144428Courtesy of CHRYSLER GROUP, LLC
  6. Install the upper intake manifold support bracket (2). Tighten fasteners (1, 3) to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  7. Engage the wire harness retainer (4) to the stud (3).
    GC0144182Courtesy of CHRYSLER GROUP, LLC
  8. Install the two upper intake manifold support brackets (2). Tighten the fasteners (1, 3) to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0144665Courtesy of CHRYSLER GROUP, LLC
  9. Install the heater core return tube (1). Tighten nut (2) to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    GC0144427Courtesy of CHRYSLER GROUP, LLC
  10. Connect the following hoses to the upper intake manifold:
    • Positive Crankcase Ventilation (PCV) (7)
    • Brake booster vacuum hose (6)
    • Fuel tank vapor purge hose (3)
  11. Connect the Manifold Absolute Pressure (MAP) sensor wire harness connector (2).
  12. Connect the Electronic Throttle Control (ETC) wire harness connector (4).
  13. Secure the ETC harness to the clip (5) on the throttle body and fasten the wire harness retainer (1) to the upper intake manifold near the MAP sensor.
    GC0144507Courtesy of CHRYSLER GROUP, LLC
  14. Fasten the brake booster vacuum hose retainer (1) to the upper intake manifold.
    GC0144029Courtesy of CHRYSLER GROUP, LLC
  15. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
  16. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
  17. Tighten the clamp at the air cleaner housing (3) to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  18. Tighten the clamp (2) at the throttle body to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  19. Connect the Inlet Air Temperature (IAT) sensor wire harness connector (1).
    GC0144028Courtesy of CHRYSLER GROUP, LLC
  20. Position the engine cover (1) and secure the retaining grommets onto the ball studs.
  21. Connect the negative battery cable and tighten nut to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  22. Start the engine and check for leaks.
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