Intake Manifold: Installation

Before installing manifold. Clean all mating surfaces. Replace all O-ring gaskets with NEW gaskets. (Figure). All intake manifold fasteners and washers are to be discarded and NEW  fasteners and washers are to be used.

1. Install intake manifold onto cylinder head and tighten fasteners to 12 N.m (105 in. lbs.) in sequence shown in. (Fig 1).
   Fig 1: Identifying Intake Manifold Tightening Sequence

   Courtesy of DAIMLERCHRYSLER CORP.
2. Install intake manifold to lower support bracket bolts. (Figure). Tighten bolts to 11 N.m (95 in. lbs.).
3. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 N.m (200 in. lbs.).
4. Connect PCV and brake booster hoses.
5. Inspect quick connect fittings for damage, replace if necessary. (Refer to FUEL SYSTEMS ). Apply a light amount of clean engine oil to fuel inlet tube. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
6. Connect Manifold Absolute Pressure (MAP) Sensor wiring connector. (Figure).
7. Connect knock sensor connector, and wiring at starter.
8. Install inlet air duct to intake manifold and throttle body. Tighten clamp to 3 N.m (30 in. lbs.).
9. Connect negative cable to battery.
10. With the DRB 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.