Intake Manifold: Service and Repair

INTAKE MANIFOLD

REMOVAL - UPPER
1. Disconnect negative cable from battery
2. Disconnect connector from inlet air temperature sensor.
3. Disconnect air intake tube at throttle body and remove upper air cleaner housing.
4. Disconnect connector from throttle position sensor (TPS).
5. Disconnect connector from idle air control (IAC) motor.
6. Disconnect connector from MAP sensor.
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 (if equipped) and cables from throttle lever and bracket.
10. Remove the EGR tube.
11. Remove the upper manifold support bracket bolt to manifold.
12. Remove engine oil dipstick from tube.
13. Remove upper intake manifold bolts. Remove upper intake manifold.

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

REMOVAL - LOWER
1. Disconnect negative cable from battery.
2. Disconnect connector from inlet air temperature sensor.
3. Disconnect air intake tube at throttle body and remove upper air cleaner housing.
4. Disconnect connector from throttle position sensor (TPS).
5. Disconnect connector from idle air control (IAC) motor.
6. Disconnect connector from MAP sensor.
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 intake manifold fittings.
9. Disconnect throttle, speed control (if equipped), and transaxle control (if equipped) and cables from throttle lever and bracket.
10. Perform fuel system pressure release procedure before attempting any repairs.
11. Disconnect fuel line.
12. Disconnect coolant temperature sensor/fuel injector wire harness connector.
13. Disconnect fuel injector harness.
14. Remove intake manifold to cylinder head fasteners.
15. Remove the manifold from engine.

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

16. Inspect the manifold.

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

INSTALLATION - LOWER
If the following items were removed, install and torque to specifications:
^ Fuel rail bolts 22 Nm (200 in. lbs.)
^ Coolant outlet connector bolts 28 Nm (250 in. lbs.)
^ Coolant temperature sensor 7 Nm (60 in. lbs.)

1. Position a new gasket on cylinder head and install lower manifold.

Fig. 95 Lower Intake Manifold Tightening Sequence:

2. Install and tighten intake manifold fasteners to 28 Nm (250 in. lbs.) in the sequence shown. Repeat procedure until all bolts are at specified torque.
3. Install lower intake manifold support bracket bolts.
^ Bolts to intake 28 Nm (250 in. lbs.)
^ Bolt to engine block 54 Nm (40 ft. lbs.)

4. Connect the fuel line.
5. Connect coolant temperature sensor/fuel injector wiring harness electrical connector.
6. Install the radiator upper and heater supply hoses.
7. Install the upper intake manifold.
8. Fill the cooling system.

INSTALLATION - UPPER
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.

Fig. 94 Upper Intake Manifold Tightening Sequence - 2.4L:

3. Install upper intake manifold and tighten fasteners to 28 Nm (250 in. lbs.) in sequence shown. Repeat this procedures until all fasteners are at specified torque.
4. Install engine oil dipstick.
5. Install upper bolt in intake manifold to front support bracket.
6. Install EGR tube.
7. Install throttle cables in bracket.
8. Connect throttle, speed control, (if equipped), 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.
14. Connect negative cable to battery