Manifold

1. Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 Nm (200 inch lbs.) torque.





2. Place the 4 plastic locator dowels into the holes in the block.
3. Apply Mopar (R) Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be slightly higher than the crossover gaskets, approximately 5 mm (0.2 inch).
4. Install the front and rear cross-over gaskets onto the dowels.





5. Install the flange gaskets. Ensure that the vertical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs. The words MANIFOLD SIDE should be visible on the center of each flange gasket.
6. Carefully lower intake manifold into position on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to position the intake manifold. After intake manifold is in place, inspect to make sure seals are in place.





7. The following torque sequence duplicates the expected results of the automated assembly system. Install the intake manifold bolts and tighten as follows:
^ Step 1-Tighten bolts 1 through 4, in sequence, to 8 Nm (72 inch lbs.) torque. Tighten in alternating steps 1.4 Nm (12 inch lbs.) torque at a time.
^ Step 2-Tighten bolts 5 through 12, in sequence, to 8 Nm (72 inch lbs.) torque.
^ Step 3-Check that all bolts are tighten to 8 Nm (72 inch lbs.) torque.
^ Step 4-Tighten all bolts, in sequence, to 16 Nm (12 ft. lbs.) torque.
^ Step 5-Check that all bolts are tighten to 16 Nm (12 ft. lbs.) torque.
8. Install closed crankcase ventilation and evaporation control systems.
9. Connect the coil wires.
10. Connect the heat indicator sending unit wire.
11. Connect the heater hoses and bypass hose.
12. Install distributor cap and wires.
13. Hook up the return spring.
14. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
15. Install the fuel lines and fuel rail.
16. Install the support bracket to the intake manifold and the mounting bracket.
17. Install the generator and drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 Nm (200 inch lbs.) torque.
18. Install the air cleaner.
19. Install the engine cover.
20. Fill cooling system. Refer to Cooling System.
21. Connect the negative cable to the battery.