Installation
1. Clean all surfaces of cylinder block and cylinder heads.
2. Place a drop (about 1/4 inch diameter) of Mopar (R) Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners.
WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury, handle with care.
3. Carefully install the intake manifold gasket. Tighten end seal retainer screws to 12 Nm (105 inch lbs.) torque.
4. Install intake manifold and (8) bolts and tighten to 1 Nm (10 inch lbs.) torque. Then tighten bolts to 22 Nm (200 inch lbs.) torque in sequence shown in the illustration. Then tighten again to 22 Nm (200 inch lbs.) torque. After intake manifold is in place, inspect to make sure seals are in place.
5. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
6. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws to 22 Nm (200 inch lbs.) torque.
7. Attach electrical connectors to fuel injectors.
8. Connect fuel supply and return tubes to fuel rail. Place clamp over fuel tubes and install retaining screw.
9. Remove cover from intake manifold. Place plenum with new gasket on intake manifold. Loosely install mounting bolts.
10. Place a new gasket on the EGR tube flange. Loosely install EGR. tube mounting screws.
11. Tighten Intake Manifold Plenum mounting bolts to 28 Nm (250 inch lbs) in sequence shown in illustration.
12. Tighten EGR tube mounting screws.
13. Connect hoses to PCV valve and brake booster nipple.
14. Attach electrical connectors to the MAP sensor and EGR transducer solenoid.
15. Attach electrical connectors to throttle position sensor and idle air control motor.
16. Install throttle cable and speed control cable in bracket.
17. Hold throttle body lever in wide-open position. Install throttle and speed control cables.
18. Connect purge hose to throttle body.
19. Connect air tube from air cleaner and throttle body.
20. Fill cooling system.