Initially, check the sealing areas and see if the gaskets for the upper intake manifold are not damaged so you can re-use them after cleaning. Insert the gasket into the upper manifold and close the two manifolds together. Fasten the manifold to the valve cover with bolts in the correct sequence until you reach 12 Nm (105 in. lbs.). Then, attach the PCV,
Brake Booster and vapor purge hoses. Don't scrape the
EGR Valve mounting surface with metal tools so as not to hurt it and prevent a reliable seal and keep the EGR valve completely clear of any debris during cleaning to avoid having it leak and cause the engine to idle roughly. Before detaching the
EGR Tube, check and clean its gaskets and add new rubber silicone seals to the intake manifold end when reinstalling. Your new silicone rubber seal should be attached 17 mm (0.67 in.) away from the flange on the intake manifold end of the EGR tube. Oil the hole in the intake manifold where the EGR mounting tube will go with Mopar. When you install rubber bushings, use lube, but do not lubricate either the EGR tube or EGR seal. Securely attach the EGR tube into the intake manifold so that the silicone rubber seals are untouched and set properly. Put in a new gasket between the EGR valve and the tube and fasten it with 15 Nm (11 ft. lbs.) of torque. Applying the EGR tube flange up to 2 mm (0.08 in.) away from the intake manifold is still considered sufficient for a decent seal. Attach the electrical connectors to the Manifold Absolute Pressure (MAP) Sensor, Electronic Throttle Control and the Manifold Tuning Valve. Connect the throttle body air inlet hose and the air cleaner housing, put back the negative
Battery Cable and tighten the nut on the negative terminal to 5 Nm (45 in. lbs.).