Before you do any work on the intake manifold upper, always remember to disconnect the negative
Battery Cable. Put your work on hold and remove the throttle body air inlet hose and air cleaner housing assembly. Remove the connectors on the Manifold Absolute Pressure (MAP) Sensor, Electronic Throttle Control and Manifold Tuning Valve. Remove the air line hoses from the Vapor Purge, Brake Booster and Positive Crankcase Ventilation (PCV) hoses. Remove the backing brackets that hold the manifolds in place and remove the
EGR Tube from both parts. Take out the manifold attaching bolts and together with the foam insulator, then examine the manifold. Clean the area where the gaskets fit and check for any damage on the gaskets themselves. Place the upper manifold gasket and fasten the upper manifold onto the lower manifold. Install the manifold attaching bolts and tighten them using the correct order up to 12 Nm (105 in. lbs.). Put back the PCV, brake booster and vapor purge hoses and while cleaning the
EGR Valve area, clean it by hand or use a very soft brush-do not use a metal scraper. When you are cleaning the EGR valve, make sure no foreign materials enter it, since that could result in a valve leak and cause your engine to perform worse. After wiping and checking the seal surfaces, add new rubber silicone seals to the EGR tube at the intake manifold whenever you remove it. Apply the new silicone rubber seal near the tube flange which is 17 mm (0.67 in.) from the EGR mounting tube hole. Then grease the inside of this hole with Mopar. Rubber Bushing Installation, remembering not to put lube near the EGR tube or seal. Insert the EGR tube into the intake manifold, being sure the silicone rubber seals are in the right location. First, put a new gasket between the EGR valve and tube and make sure to tighten the bolts to a torque of 15 Nm (11 ft.lbs.). A seal between the EGR tube and the intake manifold can be achieved, regardless of the up-to-2-mm (0.08-in.) gap between them. Connect the electrical wires back to the
MAP Sensor, Electronic Throttle Control and Manifold Tuning Valve. Next, reconnect the air inlet hose and air cleaner housing to the right places, reinstall the negative battery cable and tighten the nut on it to 5 Nm (45 in. lbs.).