Installation

1. Clean all surfaces of cylinder block and cylinder heads.





2. Place a drop (approximately 1/4 inch diameter) of Mopar (R) Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners.





3. Carefully install the new intake manifold gasket. Torque end seal retainer screws to 12 Nm (105 inch lbs.).

Intake Manifold Bolts Location And Tightening Sequence:

4. Install intake manifold and bolts and torque to 1 Nm (10 inch lbs.). Then torque bolts to 22 Nm (200 inch lbs.) in sequence shown. Then torque again to 22 Nm (200 inch lbs.). After intake manifold is in place, inspect to make sure seals are in place.
5. Make sure the injector holes are clean and all plugs have been removed.
6. Lube injector O-ring with a drop of clean engine oil to ease installation.





7. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.





8. Install the fuel rail attaching bolts and torque to 22 Nm (200 inch lbs.).
9. Install fuel tube retaining bracket screw and torque to 4 Nm (35 inch lbs.).





10. Connect cam sensor and coolant temperature sensor.
11. Connect fuel pressure regulator vacuum line.
12. Remove covering on lower intake manifold and clean surface.
13. Place the new intake manifold gasket on lower manifold. Put upper manifold into place and install bolts and nuts finger tight.

NOTE: At no time should the studs be replaced with a bolt and washer.

14. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. (Do not torque.)





15. Torque intake manifold bolts to 28 Nm (250 inch lbs.) following torque sequence.
16. Torque generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.).





17. Torque the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.).
18. Connect ground strap and MAP sensor electrical connectors.





19. Connect vacuum harness to intake plenum.
20. Using a new gasket, connect the EGR tube flange to the intake manifold and torque to 22 Nm (200 inch lbs.).
21. Clip wiring harness into the hole in the throttle cable bracket.





22. Connect the wiring connectors to the Throttle Position Sensor (TPS) and Automatic Idle Speed (AIS) motor.
23. Connect vacuum harness to throttle body.





24. Install the Direct Ignition System (DIS) coils. Torque fasteners to 12 Nm (105 inch lbs.).





25. Lubricate the end of the chassis fuel tube with 30 WT oil. Connect fuel supply hose to chassis fuel tube assembly. Pull back on the quick connect fitting to ensure complete insertion.
26. Install throttle cable.
27. Connect fuel injector wiring harness.
28. Install air cleaner and hose assembly.
29. Connect negative battery cable.
30. With the Diagnostic Readout Box (DRB) Scan Tool use Auto Shutdown (ASD) Fuel System Test to pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test, The ASD Relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.