The first step in replacing the intake manifold is to put a small bead of Mopar(R) Engine RTV GEN II onto all four corners where the manifold meets the cylinder head gasket. Place the intake manifold gasket onto the manifold with care. Make sure you tighten the end seal retainer bolts to 12 Nm (105 in. lbs.). Lay the lower intake manifold on the gasket. After installation, tighten the support bolt and the harness connector support bracket, as covered by the next step. Insert the last of the intake manifold bolts and tighten them all to 1 Nm (10 in. lbs.) in the beginning. Then, tighten all in two steps to 22 Nm (200 in. lbs.) in the correct order, always making sure there are seals in place after you fit the bolts. Connected the front cover support bracket using two bolts and a nut, after tightening the nut to 22 Nm (200 in. lbs.) and the bolts to 25 Nm (18 ft. lbs.). Install the upper radiator hose and apply a light layer of engine oil to the O-ring at the nozzle end of all your injectors. Position the fuel injector nozzles into the lower intake manifold openings, lock them and fit the bolts to the fuel rail, torque them to 12 Nm (106 in. lbs.). Correctly mount and link the connectors on the fuel injector electrical harness. Put the heater supply hose together with the ECT sensor's electrical connection. Attach the
Ignition Coil and the bracket and afterward, join the fuel supply hose to the fuel rail. Attach the upper intake manifold as well as the
EGR Tube. Add coolant to the cooling system, clip the negative battery cable in place and tighten the nut on the cable to 45 in. lbs. You should also use the ASD Fuel System Test to pressurize the fuel system wand check for possible leaks.