Upper
INTAKE MANIFOLD UPPER
1. Clean and inspect sealing surfaces. Gaskets can be reused, if free of cuts or tears.
NOTE: Make sure fuel injectors and wiring harnesses are in correct position to not interfere with upper manifold installation.
2. Install upper manifold gasket.
3. Position upper manifold onto lower manifold.
4. Install manifold attaching bolts and tighten in sequence shown to 12 Nm (105 in. lbs.).
5. Connect PCV, brake booster, and vapor purge hoses.
CAUTION: Do Not use metal scrapers when cleaning the mounting surface of the EGR valve. Damage from scratching the surface may cause an improper seal.
CAUTION: Do not allow debris to enter the EGR valve when cleaning the mounting surface. Debris can lodge between the pintle and the seat causing valve leakage that results in rough idle and depressed manifold vacuum.
6. Clean and inspect gasket sealing surfaces.
NOTE: Install new rubber silicone seals on intake manifold end of EGR tube any time it is removed from the intake manifold.
7. Install new silicone rubber seal (1) on the intake manifold end of the EGR tube. Position seal 17 mm (0.67 in.) from the tube flange.
8. Lubricate the EGR mounting tube hole in the intake manifold with Mopar(R) Rubber Bushing Installation Lube. Do not lubricate the EGR tube or seal.
9. Install the EGR tube (3) into the intake manifold (2) being careful not to damage the silicone rubber seals, and verify that the seals are correctly positioned in the intake manifold.
10. Install new gasket between the EGR valve and tube and install bolts (2). Tighten bolts to 15 Nm (11 ft. lbs.).
NOTE: The EGR tube flange (1) does not need to be flush with the intake manifold (2) to be sealed. The EGR tube flange can be up to 2 mm (0.08 in.) from intake manifold and still be sealed. This design allows the EGR tube position to vary with the tolerance stack up and remain properly sealed.
11. Connect electrical connectors to the following components:
- Manifold Absolute Pressure (MAP) Sensor
- Electronic Throttle Control
- Manifold Tuning Valve
12. Install throttle body air inlet hose and air cleaner housing assembly Air Cleaner Body - Installation.
13. Connect negative battery cable and tighten nut to 5 Nm (45 in. lbs.).