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Home >> Chrysler >> 2021 >> Voyager LXi, Gas >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> 3.6L Engine (Service Information) >> Manifolds >> Manifold, Intake >> Removal And Installation >> Upper Intake Manifold >> Installation

Upper Intake Manifold: Installation

GC0177413Courtesy of CHRYSLER GROUP, LLC
NOTE:

Prior to installing the upper intake manifold, verify that the four fuel rail bolts (1) were not inadvertently loosened. If loosened, the bolts must installed to the proper specification. Refer to RAIL, FUEL, REMOVAL AND INSTALLATION .

  1. Clean and inspect the upper seals of the lower intake manifold assembly, and replace only if necessary.
    GC0173670Courtesy of CHRYSLER GROUP, LLC
  2. Clean and inspect the sealing surfaces. Install the upper to lower intake manifold gaskets.
    GC0177479Courtesy of CHRYSLER GROUP, LLC
  3. Make sure the fuel injectors and wiring harnesses (1) are in the correct position so that they do not interfere with the upper intake manifold installation.
    GC0177654Courtesy of CHRYSLER GROUP, LLC
  4. If removed, install the insulator (1) on top of the LH cylinder head cover.
  5. Lift and hold the eight upper intake attaching bolts clear of the mating surface. Back the bolts out slightly or if required, use an elastic band to hold the bolts clear of the mating surface.
  6. Position the upper intake manifold onto the lower intake manifold so that the two locating posts on the upper intake manifold align with corresponding holes in the lower intake manifold.
    Fig 1: Upper Intake Manifold Attaching Bolts Tightening Sequence
    GC0177748Courtesy of CHRYSLER GROUP, LLC
  7. Install the eight upper intake manifold attaching bolts. Tighten the bolts in the sequence shown in illustration to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0173683Courtesy of CHRYSLER GROUP, LLC
  8. Connect the EGR cooler hose (1) to the EGR valve.
  9. Connect the EGR valve wire harness connector.
    GC0177243Courtesy of CHRYSLER GROUP, LLC
  10. Install the two upper intake manifold support bracket bolts (1) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0178149Courtesy of CHRYSLER GROUP, LLC
  11. Position the support bracket onto the intake manifold stud and tighten the lower mounting bolt (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  12. Install the support bracket nut (1) and tighten the nut to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  13. Install the electric vacuum pump and bracket. Refer to PUMP, VACUUM, REMOVAL AND INSTALLATION .
    GC0177970Courtesy of CHRYSLER GROUP, LLC
  14. Connect the vapor purge line (1).
    GC0178013Courtesy of CHRYSLER GROUP, LLC
  15. Connect the evaporative purge solenoid wire harness connector (1) and attach the wire harness retainer to the manifold.
    GC0177636Courtesy of CHRYSLER GROUP, LLC
  16. Connect the brake booster (1) and attach the hose (2) to the manifold.
    GC0177984Courtesy of CHRYSLER GROUP, LLC
  17. Connect the Positive Crankcase Ventilation (PCV) (1).
    GC0173634Courtesy of CHRYSLER GROUP, LLC
  18. Connect the Electronic Throttle Control (ETC) wire harness connectors (1) and attach the wire harness retainer (2) to the ETC.
    GC0173715Courtesy of CHRYSLER GROUP, LLC
  19. Connect the Manifold Absolute Pressure (MAP) sensor (1) wire harness connectors and attach the wire harness retainer to the manifold.
  20. Install the air cleaner intake resonator. Refer to RESONATOR, AIR CLEANER, REMOVAL AND INSTALLATION .
  21. Connect the negative battery cable.
  22. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
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