300, 300C & Magnum 2006-2008, Charger 2006-2008

Intake Manifold

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Removal & Installation



2.7L Engines
Lower Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release fuel system pressure.
  4.  
  5. Disconnect negative battery cable located in trunk.
  6.  
  7. Remove upper intake manifold.
  8.  
  9. Disconnect injector electrical connectors.
  10.  
  11. Disconnect fuel supply hose from fuel rail.
  12.  
  13. Remove bolts attaching fuel rail.
  14.  
  15. Remove fuel rail and injectors as an assembly.
  16.  
  17. Remove manifold attaching bolts.
  18.  
  19. Remove lower manifold.

    Click image to see an enlarged view

    Fig. Lower intake manifold loosening/tightening sequence-2.7L engine

  20.  

To install:

  1. Check manifold for:

    Damage and cracks
     
    Gasket surface damage or warpage
     
    Damaged fuel injector ports
     

  2.  

If the manifold exhibits any of these conditions, replace the manifold.

  1. Clean and inspect sealing surfaces of cylinder head and manifold. Gaskets can be reused provided they are free of cuts or tears.
  2.  
  3. Install lower manifold gasket.
  4.  
  5. Position manifold on cylinder head surfaces.
    NOTE
    For ease of installing upper intake manifold, install a bolt 2-3 turns to the rearmost attaching hole of intake. This will properly position lower manifold.

  6.  
  7. Install fuel rail with injectors and start bolts.
  8.  
  9. Install manifold attaching bolts and tighten in sequence shown in to 105 inch lbs. (12 Nm). Remove bolt used for aligning manifold.
  10.  
  11. Connect the fuel injector electrical connectors.
    NOTE
    Make sure fuel injectors are located in the correct location and position, as upper intake manifold interference could occur.

  12.  
  13. Connect fuel supply hose to fuel rail.
  14.  
  15. Install upper intake manifold.
  16.  

Upper Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove throttle body air inlet hose and air cleaner housing assembly.
  6.  
  7. Disconnect electrical connectors from the following components:

    Manifold Absolute Pressure (MAP) Sensor
     
    Electronic Throttle Control
     
    Manifold Tuning Valve
     

  8.  
  9. Disconnect vapor purge hose, brake booster hose, positive crankcase ventilation (PCV) hose.
  10.  
  11. Remove manifold support brackets.
  12.  
  13. Remove manifold attaching bolts.
  14.  
  15. Remove the upper manifold.
  16.  
  17. Remove foam insulator.
  18.  
  19. Check manifold for:

    Damage and cracks
     
    Gasket surface damage or warpage
     
    Damaged or clogged EGR ports
     

  20.  
  21. If the manifold exhibits any damaged or warped conditions, replace the manifold. Clean EGR ports as necessary.

    Click image to see an enlarged view

    Fig. Upper intake manifold loosening/tightening sequence-2.7L engine

  22.  

To install:

  1. Clean and inspect sealing surfaces. Gaskets can be reused, if free of cuts or tears.
    NOTE
    Make sure fuel injectors and wiring harnesses are in correct position to not interfere with upper manifold installation.

  2.  
  3. Install the upper manifold gasket.
  4.  
  5. Position the upper manifold onto lower manifold.
  6.  
  7. Install manifold attaching bolts and tighten in sequence shown in to 105 inch lbs. (12 Nm).
  8.  
  9. Connect PCV, brake booster, and vapor purge hoses.
  10.  
  11. Connect electrical connectors to the following components:

    Manifold Absolute Pressure (MAP) Sensor
     
    Electronic Throttle Control
     
    Manifold Tuning Valve
     

  12.  
  13. Install throttle body air inlet hose and air cleaner housing assembly.
  14.  

3.5L Engine
Lower Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Perform fuel pressure release procedure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the upper radiator hose from thermostat housing.
  8.  
  9. Remove the upper intake manifold.
  10.  
  11. Reposition power steering fluid reservoir and bracket.
  12.  
  13. Disconnect the electrical connectors to fuel injectors and coolant temperature sensor.
  14.  
  15. Disconnect heater hose from the rear intake manifold.
  16.  
  17. Disconnect the coolant container hose at the rear intake manifold.
  18.  
  19. Disconnect the fuel supply hose from fuel rail.
  20.  
  21. Remove the bolts attaching fuel rail.
  22.  
  23. Remove fuel rail and injectors as an assembly.
  24.  
  25. Remove bolts attaching lower intake and remove intake manifold.

    Click image to see an enlarged view

    Fig. Lower intake manifold and gasket-3.5L engine



    Click image to see an enlarged view

    Fig. Lower intake manifold torque sequence-3.5L engine

  26.  

To install:

  1. Clean all sealing surfaces.
  2.  
  3. Position new gaskets and intake manifold on cylinder head surfaces.
  4.  
  5. Install intake manifold bolts and gradually tighten in sequence shown until a torque of 21 ft. lbs. (28 Nm is obtained.
  6.  
  7. Install fuel rail and injectors as an assembly.
  8.  
  9. Connect fuel supply hose to fuel rail.
  10.  
  11. Connect heater hose to rear lower intake manifold.
  12.  
  13. Connect coolant container hose to the rear lower intake manifold.
  14.  
  15. Connect electrical connectors to fuel injectors and coolant temperature sensor.
  16.  
  17. Install power steering fluid reservoir and bracket.
  18.  
  19. Install upper intake manifold.
  20.  
  21. Connect the upper radiator hose to thermostat housing.
  22.  
  23. Fill the cooling system.
  24.  

Upper Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Disconnect the IAT sensor electrical connector.
  6.  
  7. Remove air inlet hose from the throttle body.
  8.  
  9. Disconnect the MAP sensor electrical connector.
  10.  
  11. Separate the engine electrical harness connectors from the intake manifold.
  12.  
  13. Disconnect the EGR tube, PCV, purge and power brake booster vacuum hoses from the upper intake manifold.
  14.  
  15. Disconnect the electronic throttle control electrical connector.
  16.  
  17. Remove the throttle bracket fasteners from the throttle body and cylinder head.
  18.  
  19. Disconnect electrical connectors from the Manifold Tuning Valve (MTV) and Short Runner Valve.
  20.  
  21. Remove the right intake manifold support brackets.
  22.  
  23. Remove the upper intake manifold retaining bolts, insulation foam pad and manifold. Clean all gasket sealing surfaces.

    Click image to see an enlarged view

    Fig. Right upper intake manifold (1) support brackets (2)-3.5L engine

  24.  

To install:

  1. Clean and inspect gasket sealing surfaces.
  2.  
  3. Position new gasket.
  4.  
  5. Install the upper intake manifold insulator foam.
  6.  
  7. Install the upper intake manifold. Tighten bolts to 105 inch lbs. (12 Nm) starting in the center working outward in a cross sequence pattern.
  8.  
  9. Install the right manifold support brackets. Tighten fasteners to 105 inch lbs. (12 Nm).
  10.  
  11. Install the throttle bracket. Tighten fasteners to 105 inch lbs. (12 Nm) at the throttle body and 21 ft. lbs. (28 Nm) at the cylinder head.
  12.  
  13. Connect the manifold tuning valve and short runner valve electrical connectors.
  14.  
  15. Connect the electronic throttle control harness connector.
  16.  
  17. Connect the engine electrical connectors to the intake manifold.
  18.  
  19. Connect the EGR tube, PCV, purge and power brake booster vacuum hoses to the intake manifold.
  20.  
  21. Connect the MAP sensor harness connector.
  22.  
  23. Install the inlet hose and connect the IAT sensor harness connector.
  24.  
  25. Connect negative battery cable.
  26.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove engine cover.
  4.  
  5. Bleed fuel system.
  6.  
  7. Disconnect negative cable from battery.
  8.  
  9. Remove air inlet hose.
  10.  
  11. Remove ignition wires from on top of intake manifold.
  12.  
  13. Disconnect electrical connectors for the following components:

    Manifold Absolute Pressure (MAP) Sensor
     
    Fuel Injectors
     
    ETC (Electric Throttle Control)
     

  14.  
  15. Remove wire harness from intake manifold.
  16.  
  17. Disconnect brake booster hose, purge hose, and MUA hose (Make Up Air Hose).
  18.  
  19. Remove EGR tube from intake manifold.
  20.  
  21. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts.
  22.  
  23. Remove intake manifold as an assembly.
  24.  

To install:


NOTE
There is no approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.

Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.

  1. Inspect the intake sealing surface for cracks, nicks and distortion.
  2.  
  3. Inspect the intake manifold vacuum hose fittings for looseness or blockage.
  4.  
  5. Position intake manifold.
  6.  
  7. Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a criss-cross pattern. Torque fasteners to 105 inch lbs. (12 Nm).
  8.  
  9. Install EGR tube.
  10.  
  11. Install wire harness on intake manifold.
  12.  
  13. Connect electrical connectors for the following components:

    Manifold Absolute Pressure (MAP) Sensor
     
    Fuel Injectors
     
    ETC (Electronic Throttle Control)
     

  14.  
  15. Install ignition wires.
  16.  
  17. Connect Brake booster hose, purge hose, and MUA hose (Make Up Air hose).
  18.  
  19. Install air inlet hose.
  20.  
  21. Connect negative cable to battery.
  22.  
  23. Install engine cover.
  24.  

 
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