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Intake Manifold - Lower: Installation

WARNING: This page is about a different car, the 2003 Dodge Intrepid, 2003 Chrysler Intrepid, 2003 Chrysler Concorde, and 2003 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean all sealing surfaces.
    NOTE: Gaskets can be reused provided they are free of tears or cuts.
  2. Inspect gaskets for tears or cuts. Replace as necessary.
  3. Position gaskets and intake manifold on cylinder head surfaces.
  4. Install fuel rail with injectors.
  5. Install intake manifold bolts and gradually tighten in sequence shown in (Fig 1) until a torque of 28 N.m (250 in. lbs.) is obtained.
    Fig 1: Tightening Lower Intake Manifold Bolts
    G02709837Courtesy of DAIMLERCHRYSLER CORP.
  6. Install screw attaching fuel rail support bracket to the throttle body support bracket.
  7. Connect fuel supply hose to fuel rail.
  8. Connect heater and coolant bottle supply hoses to coolant tube at rear of intake manifold (Figure).
  9. Connect electrical connectors to fuel injectors and coolant temperature sensor.
  10. Install the upper intake manifold. (Refer to INTAKE MANIFOLD - UPPER ).
  11. Connect the radiator upper hose to the coolant outlet at front of lower manifold.
  12. Fill the cooling system. (Refer to STANDARD PROCEDURE ).
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