Upper Intake Manifold

INTAKE MANIFOLD UPPER

REMOVAL
1. Disconnect negative cable from battery.

Fig.104:

2. Disconnect connector from inlet air temperature sensor (Fig. 104).
3. Disconnect air intake tube at throttle body and remove upper air cleaner housing.

Fig.106:

4. Disconnect connector from Throttle Position Sensor (TPS) (Fig. 106).
5. Disconnect connector from idle Air Control (AC) motor (Fig. 106).

Fig.105:

6. Disconnect connector from MAP sensor (Fig. 105).
7. Remove vacuum lines for purge solenoid and PCV valve at intake manifold.
8. Remove vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold fittings.
9. Disconnect throttle, speed control (if equipped), and transaxle control (31 TH equipped only) cables from throttle lever and bracket.
10. Remove the EGR tube.

Fig.107:

11. Remove the upper manifold support bracket bolt to manifold (Fig. 107).
12. Remove engine oil dipstick from tube.

Fig.108:

13. Remove upper intake manifold bolts (Fig. 108). Remove upper intake manifold.

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

INSPECTION
1. Check manifold surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 inch per foot) of manifold length.
2. Inspect manifold for cracks or distortion. Replace manifold if necessary.

INSTALLATION
1. Clean manifold sealing surfaces.
2. Apply a 1.5 mm (0.060 in.) bead Mopar Gasket Maker to the perimeter of the lower intake manifold runner openings.
3. Install upper intake manifold and tighten fasteners to 28 Nm (250 in. lbs.) in sequence shown in (Fig. 108). Repeat this procedure until all fasteners are at specified torque.
4. Install engine oil dipstick.
5. Install upper bolt in intake manifold to front support bracket (Fig. 107). Torque to 28 Nm (250 in. lbs.).
6. Install EGR tube.
7. Install throttle cables in bracket.
8. Connect throttle, speed control, (if equipped), transaxle control (31TH equipped only) cables to throttle lever.
9. Connect vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold fittings.
10. Connect vacuum lines for purge solenoid and PCV valve.
11. Connect electrical connectors for MAP sensor, Throttle Position Sensor (TPS), and Idle Air Control (IAC) motor.
12. Install air cleaner upper housing and air intake tube to throttle body.
13. Connect inlet air temperature sensor connector (Fig. 104).
14. Connect negative cable to battery.