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Installation - Lower Intake Manifold

WARNING: This page is about a different car, the 2004 Chrysler Pacifica. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean all sealing surfaces.
  2. Position new gaskets and intake manifold on cylinder head surfaces.
  3. Install intake manifold bolts and gradually tighten in sequence shown in (Fig 1 ) until a torque of 28 N.m (250 in. lbs.) is obtained.
    Fig 1: Lower Intake Manifold Tightening Sequence
    G03572598Courtesy of DAIMLERCHRYSLER CORP.
  4. Install fuel rail and injectors as an assembly.
  5. Connect fuel supply hose to fuel rail.
  6. Connect heater hose to intake manifold.
  7. Connect coolant container to thermostat housing.
  8. Install the exhaust cross over retaining bolt to the intake manifold.
  9. Connect electrical connectors to fuel injectors and coolant temperature sensor.
  10. Install power steering fluid reservoir and bracket.
  11. Install upper intake manifold (- Refer to INSTALLATION  ).
  12. Connect the upper radiator hose to the thermostat housing.
  13. Fill the cooling system (Refer to STANDARD PROCEDURE - COOLING SYSTEM FILLING ).
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