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Intake Manifold: Installation

  1. Clean the gasket surfaces of the cylinder heads and the intake manifold.
    Fig 1: Identifying Intake Manifold Components
    GC0034499Courtesy of DAIMLERCHRYSLER CORP.
  2. Position the intake manifold (1) on the cylinder heads with new gaskets (2) in place.
  3. Install the intake manifold bolts and tighten to 20 N.m (15 ft. lbs.).
  4. Install the air pump switchover valves (4). Tighten the bolts to 20 N.m (15 ft. lbs.).
    Fig 2: Identifying EGR Pipe & EGR Valve
    GC0032364Courtesy of DAIMLERCHRYSLER CORP.
  5. Connect the EGR pipe fitting (1) to the EGR valve (2). Tighten the EGR pipe fitting to 40 N.m (30 ft. lbs.).
  6. Install the mass air flow sensor. (Refer to FUEL SYSTEM/FUEL INJECTION/MANIFOLD AIR FLOW (MAF) SENSOR - INSTALLATION) .
  7. Connect the engine harness connectors.
  8. Connect the vacuum lines at the crankcase ventilator, purge valve, EGR valve, and the brake booster.
  9. Install the fuel rail with fuel injectors. (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION) .
  10. Install the air cleaner housing. (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL) .
  11. Connect the negative battery cable.
  12. Start the engine and check for leaks.
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