Intake Manifold: Service and Repair
REMOVAL1. Release fuel system pressure. See Powertrain Management/Fuel Delivery and Air Induction/Service and Repair for fuel system pressure release procedure.
Service and Repair
2. Drain cooling system. Disconnect negative cable from battery
3. Disconnect air tube from air cleaner and throttle body.
4. Hold throttle lever in wide-open position. Remove throttle cable and speed control cable from lever.
Fig. 15 Removing Throttle Cable And Speed Control Cable:
5. Compress locking tabs on throttle cable and speed control cable and remove them from bracket Fig. 15.
Fig. 16 EGR Transducer:
6. Disconnect electrical connectors from solenoid on EGR valve transducer and MAP sensor Fig. 16.
7. Disconnect the Intake Air Temperature sensor electrical connector on Flexible Fuel Vehicles (FFV) only.
8. Disconnect hose from PCV valve at rear of intake manifold plenum. Disconnect brake booster hose from nipple at rear of intake manifold plenum. Disconnect vacuum line from fuel pressure regulator.
Fig. 17 Throttle Position Sensor:
9. Disconnect purge hose from throttle body Disconnect electrical connector from throttle position sensor and idle air control motor Fig. 17.
Fig. 18 EGR Tube:
10. Remove EGR tube mounting screws at intake manifold plenum Fig. 18.
11. Remove intake manifold plenum mounting bolts. Lift Plenum up off of engine. Cover intake manifold to prevent foreign material from entering engine.
Fig. 19 Fuel Supply And Return Tubes:
12. Disconnect fuel supply and return tube quick connect fittings at the rear of intake manifold Fig. 19. See Powertrain Management/Fuel Delivery and Air Induction/Service and Repair.
Service and Repair
13. Remove screw from fuel tube clamp Fig. 19. Separate fuel tubes from bracket.
14. Rotate injectors toward center of engine. Tag the injector connectors with their cylinder number. Disconnect electrical connector from injectors.
Fig. 20 Fuel Rail:
15. Remove fuel rail mounting bolts Fig. 20.
16. Lift fuel rail straight up, off of engine. Cover fuel injector openings in intake manifold.
Fig. 21 Intake Manifold Removal And Installation:
17. Remove upper radiator hose, bypass hose and rear intake manifold hose Fig. 21.
18. Remove intake manifold bolts. Remove intake manifold.
Fig. 22 Intake Manifold Gasket:
19. Remove intake manifold seal retainers screws Fig. 22. Remove intake manifold gasket.
WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury. Handle with care.
INSTALLATION
1. Clean all surfaces of cylinder block and cylinder heads.
Fig. 23 Intake Manifold Gasket Sealing:
2. Place a drop (about 1/4 in. diameter) of Mopar Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners Fig. 23.
WARNING: Intake manifold gasket is made of very thin metal and may cause personal injury. Handle with care.
3. Carefully install the intake manifold gasket Fig. 22. Tighten end seal retainer screws to 12 Nm (105 in.lbs.) torque.
4. Install intake manifold and 8 bolts and tighten to 1 Nm (10 in.lbs.) torque. Then tighten bolts to 22 Nm (200 in.lbs.) torque in sequence shown in Fig. 21. Then tighten again to 22 Nm (200 in.lbs.) torque. After intake manifold is in place, inspect to make sure seals are in place.
5. Apply a light coating of clean engine oil to the 0-ring on the nozzle end of each injector.
6. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws to 22 Nm (200 in.lbs.) torque.
7. Attach electrical connectors to fuel injectors.
8. Connect fuel supply and return tubes to fuel rail. Place clamp over fuel tubes and install retaining screw.
9. Remove cover from intake manifold. Place plenum with new gasket on intake manifold. Loosely install mounting bolts.
10. Place a new gasket on the EGR tube flange. Loosely install EGR tube mounting screws.
Fig. 24 Intake Manifold Plenum Tightening Sequence:
11. Tighten Intake Manifold Plenum mounting bolts to 28 Nm (250 in.lbs.) in sequence as shown in Fig. 24.
Fig. 25 EGR Tube To Exhaust Manifold:
12. Tighten EGR tube mounting screws.
13. Connect hoses to PCV valve and brake booster nipple.
14. Attach electrical connectors to the MAP sensor and EGR transducer solenoid. Connect the Intake Air Temperature sensor electrical connector on Flexible Fuel Vehicles (FFV) only.
15. Attach electrical connectors to throttle position sensor and idle air control motor.
16. Install throttle cable and speed control cable in bracket.
17. Hold throttle body lever in wide-open position. Install throttle and speed control cables.
18. Connect purge hose to throttle body.
19. Connect air tube from air cleaner and throttle body
20. Fill cooling system. Refer to Cooling System/Service and Repair for procedure.
Service and Repair