Upper Manifold Replacement

REMOVAL
1. Disconnect negative cable from battery.
2. Disconnect air intake tube and resonator box from throttle body and remove.

Throttle Body Electrical Connectors:

3. Remove connector from Throttle Position Sensor (TPS).
4. Remove connector from Idle Air Control (IAC) motor.

Intake Manifold Front Support Bracket And Map Sensor:

5. Remove connector from MAP sensor.

Vacuum Line Connections:

6. Remove vacuum lines for purge solenoid and PCV valve at intake manifold.

Vacuum Fitting At Rear Of Upper Intake Manifold:

7. Remove vacuum lines for power brake booster and speed control vacuum reservoir at upper intake manifold fittings.

Throttle Cable Attachment To Throttle Body:

8. Remove throttle cable and speed control cable (if equipped) from throttle lever.
9. Remove throttle cables from bracket by compressing retaining tabs.

Intake Manifold Rear Support Bracket:

10. Remove two top bolts from intake manifold to rear support bracket and EGR tube.
11. Remove upper bolt from intake manifold to front support bracket.
12. Remove dipstick.
13. Remove dipstick tube.

CAUTION: Moving the dipstick tube will cause damage to the sealer, causing an oil leak. Dipstick tube must be sealed at cylinder block.

14. Remove upper intake manifold bolts. Remove upper intake manifold.

CAUTION: Cover intake manifold to prevent foreign material from entering engine.

INSTALLATION
1. Install new upper intake manifold gasket.

NOTE: Center outboard fastener is a double stud.

2. Tighten upper intake manifold fasteners starting at center and progressing outward in both directions. Tighten bolts to 28 Nm (250 inch lbs.). Repeat this procedures until all fasteners are at specified torque.
3. Install dipstick tube. Seal tube to cylinder block using Mopar Stud N' Bearing Mount Adhesive. Tighten dipstick tube fastener to 12 Nm (105 inch lbs.).
4. Install dipstick.
5. Install upper bolt in intake manifold to front support bracket. Torque to 28 Nm (250 inch lbs.).
6. Install a new EGR tube gasket at intake manifold connection.
7. Install two upper bolts at intake manifold to rear support bracket and EGR tube. Tighten bolts to 28 Nm (250 inch lbs.).
8. Install throttle cables in bracket.
9. Install throttle cable and speed control cable (if equipped) to throttle lever.
10. Install vacuum lines for power brake booster and speed control vacuum reservoir at upper intake manifold fittings.
11. Install vacuum lines for purge solenoid and PCV valve.
12. Install electrical connectors for MAP sensor, Throttle Position Sensor (TPS), and Idle Air Control (IAC) motor.
13. Install air intake tube and resonator box to throttle body.
14. Connect negative cable to battery