B. Replace Intake Manifold Gaskets
1. With the ignition key in the OFF position, disconnect the negative battery cable.Note:
To ensure customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
2. Drain the cooling system by opening the radiator cap and the radiator drain plug. Save the coolant for reuse.
WARNING:
Do not loosen the radiator drain plug with the system hot and under pressure. Serious burns from coolant can occur.
NOTE:
The coolant reserve/overflow tank and heater core do not need to be drained to complete this procedure.
3. Remove the accessory drive belt as follows:
a. Attach a socket/wrench to the pulley bolt of the automatic tensioner (Figure 2).
b. Relax the tension from the belt by rotating the tensioner counter clockwise as viewed from the front.
c. When all belt tension has been relaxed, remove the belt from the tensioner pulley first and then all other pulleys.
4. Disconnect the A/C compressor electrical connectors (if equipped).
5. Remove the A/C compressor brace and then disconnect the compressor bracket. Set the compressor and bracket assembly aside (if equipped).
NOTE:
It is not necessary to discharge A/C. Compressor is to be set aside for better access to the intake manifold.
6. Remove the generator brace and generator.
7. Disconnect the upper heater hose and the bypass hose. Disconnect the upper radiator hose from the thermostat housing.
8. Disconnect the thermostat housing electrical connectors.
9. Disconnect the transmission kickdown cable (if equipped).
10. Release the throttle body linkage, then remove the accelerator linkage bracket and set aside.
11. Remove the air cleaner cover and filter. Remove the air cleaner housing. Save the gasket for reuse.
12. Disconnect the throttle body vacuum hoses and electrical connectors.
13. Remove the throttle body assembly. Discard the gasket.
14. Disconnect the MAP sensor connector.
15. Release the fuel system pressure as follows:
WARNING:
Because the fuel system is under constant fuel pressure, this pressure must be released before servicing any fuel supply system component.
a. Remove and replace the fuel tank filler cap to release fuel tank pressure.
b. Remove the protective plastic cap from the pressure test port on the fuel rail at the front of the engine.
c. Obtain the fuel pressure gauge/hose assembly from the fuel pressure gauge tool set 5069. Remove the gauge from the hose.
d. Place one end of the hose into an approved gasoline container.
e. Place a shop towel under the test port.
f. To release the fuel pressure, screw the other end of the hose on to the fuel pressure test port.
g. After the fuel pressure has been released, remove the hose and install the protective cap.
16. Disconnect the fuel line as follows:
a. Clean the fitting of any foreign material before disassembly.
b. Pry up on the latch clip with a screwdriver (Figure 3).
c. Slide the latch clip toward the fuel rail while lifting with the screwdriver.
d. Remove the latch clip from the fuel rail.
e. Insert a fuel line removal tool (QTC 7660 or equivalent) into the fuel line. Use this tool to release the locking fingers in the end of the line.
f. With the tool still inserted, pull the fuel line from the fuel rail.
17. Label, then disconnect left bank ignition cables (top) from the coil pack. Remove the ignition coil/bracket assembly and set the assembly aside. Leave the right bank ignition cables (bottom) attached.
18. Disconnect the ignition cable bracket from the intake manifold and set it aside.
19. Disconnect the closed crankcase ventilation hose from the intake manifold.
20. Remove the upper intake manifold bolts (Figure 4). Retain the rear three upper intake manifold bolts in the up position with tape, rubber bands or binder clips.
21. Move the upper manifold forward and disconnect the brake booster and heater control vacuum hoses from the rear of the manifold.
22. Lift the upper intake manifold out of the engine compartment. Discard the gasket.
23. Disconnect the EGR vacuum hose. Remove the EGR transducer.
24. Disconnect the EGR tube from the lower intake manifold. Loosen the rear EGR tube connection.
25. Disconnect the fuel injector electrical connectors. Pull the harness back from the lower intake manifold.
26. Disconnect the intake manifold temperature sensor.
27. Remove the 14 lower intake manifold bolts and remove the manifold (Figure 5).
28. Remove and discard lower intake manifold gaskets and end seals.
29. Clean the intake manifold and cylinder block gasket surfaces with solvent (Mopar Brake Parts Cleaner PN 4318037 or equivalent). Blow surfaces dry with compressed air.
30. Install the provided intake manifold gaskets. Be sure that the locator pins are properly positioned and the gasket openings align with the cylinder head passages (Figure 6).
31. Peel the protective paper backing from the provided end seals and press them firmly on to the block (blue -- rear, brown -- front). Align the slots in the end seals with the notches in the intake manifold gaskets (Figure 7).
32. Apply Mopar Silicone Rubber Adhesive Sealant, PIN 4318025 or equivalent, into the four corner pockets. Fill the pocket only. Do not overfill.
IMPORTANT:
The lower intake manifold must be installed within 3 minutes of sealant application.
33. Carefully install the lower intake manifold. After the manifold is in place, inspect to make sure seals and gaskets are still properly positioned, then finger start all lower manifold bolts.
34. Tighten the lower intake manifold bolts to 40 ft-lbs (54 Nm) following the number sequence in Figure 8.
35. Connect the EGR tube to the lower manifold. Tighten the rear EGR tube bolts to 174 in-lbs (20 Nm).
36. Connect the fuel injector electrical connectors.
37. Install the fuel supply line as follows:
a. Insert the fuel line onto the fuel rail until a click is felt.
b. Verify a locked condition by firmly pulling on the fuel line and fluing.
c. Snap the provided latch clip into position. If the latch clip will not fit, the fuel line is not properly installed to the fuel rail. Recheck the fuel line connection.
38. Connect the EGR transducer and vacuum hose.
39. Connect the intake manifold temperature sensor.
40. Position the provided gasket on the lower manifold. Connect the brake booster and heater control vacuum hoses to the rear of the upper manifold.
41. Position the upper manifold on the lower manifold. Finger start all bolts, alternating from one side to the other.
42. Tighten the upper intake manifold bolts to 16 ft-lbs (22 Nm) following the number sequence in Figure 9.
43. Connect the closed crankcase ventilation hose to the upper manifold.
44. Connect the vacuum hose at the front of the upper manifold.
45. Connect the MAP sensor connector.
46. Connect the thermostat housing electrical connectors.
47. Connect the throttle body vacuum hoses and electrical connectors.
48. Using the supplied gasket, install the throttle body assembly. Install on the lower front stud first and then roll the throttle body on to the other three studs. Tighten the throttle body nuts to 200 in-lbs (23 Nm).
49. Reinstall the ignition cable bracket.
50. Install the coil/bracket assembly and attach ignition cables to the coil pack. Tighten the coil bracket bolts to 190 in-lbs (21 Nm).
51. Install the accelerator linkage bracket. Connect the throttle body linkage and transmission kickdown cable (if equipped).
52. Connect the upper heater hose and bypass hose.
53. Install the generator. Tighten the brace bolts to 30 ft-lbs (41 Nm).
54. Install the A/C compressor/bracket assembly and brace (if equipped). Tighten the bolts to 30 ft-lbs (41 Nm).
55. Install the accessory drive belt as follows:
CAUTION:
When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction.
a. Position the drive belt over all pulleys except tensioner pulley. Refer to Figure 10 for correct routing.
b. Attach a socket/wrench to pulley mounting bolt of automatic tensioner.
c. Rotate socket/wrench counter clockwise as viewed from the front. Install belt over tensioner pulley, then let tensioner rotate back into place.
d. Remove wrench and be sure belt is properly seated on all pulleys.
56. Install the air cleaner housing. Reuse the original gasket.
57. Install the air filter and air cleaner cover.
58. For vehicles equipped with A/C only: Inspect the upper radiator hose for wear near the NC compressor manifold. Replace the upper radiator hose with PN 52028641 only if wear is sufficient to expose the hose reinforcement cords.
59. For vehicles equipped with A/C only: Slide the provided protective sleeve over the upper radiator hose. Position the sleeve so that it covers the area shown in Figure 11. Secure both ends of the sleeve with electrical tape.
NOTE:
If radiator hose has a protective sleeve on it, it must be replaced with the provided sleeve.
60. Install the upper radiator hose on the thermostat housing and secure with clamp. Align the white paint mark on the hose with the thermostat mounting bolt (Figure 12).
61. For vehicles equipped with A/C only: Snap the provided protective cover over the NC compressor manifold (Figure 13).
62. Reconnect the negative battery cable.
63. Refill cooling system as follows:
a. Close radiator drain plug.
b. Refill cooling system using original coolant and install radiator cap.
c. Start and operate engine until thermostat opens. Add 50/50 coolant/water mixture as necessary to coolant reserve/overflow bottle. The level in the tank should be between the ADD and FULL marks.