300M, Concorde, Intrepid, LHS, 1998-2004

Intake Manifold

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Removal & Installation



2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect the air tube from the air cleaner and the throttle body.
  10.  
  11. Hold the throttle lever in the wide-open position and remove the throttle cable and the speed control cable from the lever. Compress the locking tabs on the cables and remove them from the mounting brackets.
  12.  
  13. Unplug the electrical connections from the following:
    NOTE
    Cover the lower part of the intake manifold to prevent foreign material from entering the engine.



    Solenoid on the Exhaust Gas Recirculation (EGR) valve transducer
     
    Manifold Absolute Pressure (MAP) sensor
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Vacuum hose from the Positive Crankcase Ventilation (PCV) valve as well as the power brake booster at the intake manifold nipple
     
    Vacuum line at the fuel pressure regulator
     
    Purge hose from the throttle body
     
    Electrical connector from the TP sensor and the IAC motor
     
    EGR tube-to-intake manifold plenum screws
     
    Intake manifold plenum (upper part of the manifold)
     



    Fuel supply and return tubes from the fuel rail at the rear of the intake manifold
     

  14.  
  15. Disconnect the fuel/return tubes by pushing the quick-connect fitting toward the fuel tube while depressing the built-in disconnect tool with Quick-Connect Fitting tool 6751. To disconnect the fitting from the fuel rail, slightly twist the fitting while maintaining downward pressure on tool 6751. Wrap shop towels around the fuel hoses to absorb any fuel spillage.
  16.  
  17. Plug the fuel line openings to prevent system contamination.
  18.  
  19. Remove or disconnect the following:

    Fuel clamp screw and tubes from the bracket
     
    Electrical harness from the injectors and turn toward the center of the engine
     
    Fuel rail mounting bolts and lift the fuel rail with the injectors attached straight up and off the engine. Cover the injector openings.
     
    Intake manifold bolts and the manifold
     
    Intake manifold seal retainer screws and intake manifold gasket
     

  20.  
  21. Clean all mating surfaces.
  22.  
  23. Inspect the manifold for damage, cracks or clogged passages. Repair, clean or replace the manifold as required.
  24.  

To install:

Click image to see an enlarged view

Fig. Intake manifold loosening and tightening sequence-2.7L engine

  1. Verify that all intake manifold and cylinder head sealing surfaces are clean. Place a drop of sealant onto each of the 4 corners of the intake manifold gasket, where the cylinder head meets the engine block.
    CAUTION
    The intake manifold gasket is made of very thin metal and can cause cuts if handled carelessly.

  2.  
  3. Install the intake manifold and 8 mounting bolts. Snug down evenly to just 10 inch lbs. (1.1 Nm).
  4.  
  5. Torque the lower intake manifold bolts in the proper sequence to 105 inch lbs. (12 Nm).
  6.  
  7. Install the fuel injectors by performing the following procedure:
    1. Apply a light coat of clean engine oil to the O-ring on the nozzle end of each injector.
    2.  
    3. Insert the fuel injector nozzles into the openings in the intake manifold. Seat the injectors in place and install the fuel rail mounting bolts, torque to 16 ft. lbs. (22 Nm).
    4.  

  8.  
  9. Install or connect the following:

    Electrical connectors to each fuel injector. Rotate the injectors toward the cylinder head covers.
     
    Fuel supply and return tubes to the fuel rail. Be sure that the black plastic release ring to the quick-connect fitting is in the OUT position. Place special tool 6751 under the largest diameter of the quick-connect fitting.
     

  10.  
  11. Pull tool 6751 toward the fuel rail until the quick-connect fitting clicks into place. Place the special tool between the shoulder of the built-in disconnect tool and top of the quick-connect fitting, then inspect the security of the fitting by applying a slight downward force against the fitting. It should be locked in place.

    Click image to see an enlarged view

    Fig. Intake plenum tightening sequence-2.7L engine



    Intake plenum with new gasket onto the intake manifold. Loosely install the mounting bolts.
     
    EGR tube to the manifold with a new gasket in place. Loosely install the mounting screws.
     
    Torque the intake manifold plenum mounting bolts to 105 inch lbs. (12 Nm) following the outlined sequence
     
    Left and right support brackets to the manifold and torque the lower fasteners to 50 inch lbs. (6 Nm) and the upper fasteners to 105 inch lbs. (12 Nm)
     
    EGR tube mounting bolts
     
    PCV valve hose and power brake booster hose
     
    Electrical connectors to the EGR transducer solenoid, IAC motor, MAP and TP sensors
     
    Throttle cable and speed control cable to the mounting bracket and connect to the throttle body lever while holding lever in the wide-open position
     
    Purge hose to the throttle body
     
    Reconnect the air tube to the air cleaner and the throttle body
     
    Negative battery cable
     

  12.  
  13. Change the engine oil and oil filter.
  14.  
  15. Fill the cooling system. Run the vehicle with the radiator cap removed until the thermostat opens, adding coolant as required. Watch for fuel and coolant leaks and for correct engine operation.
  16.  
  17. Once the vehicle has cooled, recheck the coolant level and add, if necessary.
  18.  

3.2L Engine
Lower
  1. Perform fuel pressure release.
  2.  
  3. Drain cooling system.
  4.  
  5. Remove upper intake manifold.
  6.  
  7. Disconnect electrical connectors to fuel injectors and coolant temperature sensor.
  8.  
  9. Disconnect heater hose quick connect tee from heater tube at rear of manifold.
  10.  
  11. Disconnect fuel supply hose from fuel rail.
  12.  
  13. Remove screw attaching fuel rail support bracket to the throttle body support bracket.
  14.  
  15. Remove bolts attaching fuel rail.
  16.  
  17. Remove fuel rail and injectors as an assembly.
  18.  
  19. Remove bolts attaching lower intake and remove intake manifold.
  20.  

To install:

  1. Clean all sealing surfaces
    NOTE
    Gaskets can be reused provided they are free of tears or cuts.

  2.  
  3. Inspect gaskets for tears or cuts. Replace as necessary.
  4.  
  5. Position gasket and intake manifold on cylinder head surfaces.
  6.  
  7. Install fuel rail with injectors.

    Click image to see an enlarged view

    Fig. The proper torque sequence

  8.  
  9. Install intake manifold bolts, and gradually tighten in sequence until a torque of 250 inch lbs. (28 Nm) is obtained
  10.  
  11. Install screw attaching fuel rail support bracket to the throttle body support bracket.
  12.  
  13. Connect fuel supply hose to fuel rail.
  14.  
  15. Connect heater hose quick connect tee to heater tube at rear of manifold.
  16.  
  17. Connect electrical connectors to fuel injectors and coolant temperature sensor.
  18.  
  19. Install upper intake manifold. Refer to procedure in this section.
  20.  
  21. Fill cooing system.
  22.  
  23. With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks
    CAUTION
    When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.

  24.  

Upper
  1. Disconnect negative cable from remote jumper terminal.
  2.  
  3. Remove air cleaner housing and inlet hose
  4.  
  5. Remove throttle and speed control cables from throttle arm and bracket.
  6.  
  7. Disconnect electrical connectors from the following sensors and actuators:


    1. Secondary Runner Valve (SRV)
    2.  
    3. Manifold Tuning Valve (MTV)
    4.  
    5. Throttle Position Sensor (TPS)
    6.  
    7. Idle Air Control (IAC)
    8.  
    9. Intake Air Temperature/Manifold Absolute Pressure (TMAP)
    10.  

  8.  
  9. Disconnect vacuum hoses from the following:


    1. Secondary Runner Valve (SRV) Reservoir
    2.  
    3. Speed Control Reservoir
    4.  
    5. Positive Crankcase Ventilation (PCV) Valve
    6.  

  10.  
  11. Remove right and left side intake manifold supports.

    Click image to see an enlarged view

    Fig. Remove support brackets at intake manifold front corners and at MTV

  12.  
  13. Remove support brackets at intake manifold front corners and at MTV
  14.  
  15. Loosen upper fastener attaching throttle body to support bracket.
  16.  
  17. Remove clips attaching EGR tubes to intake manifold.
  18.  
  19. Remove bolts attaching intake manifold and remove manifold
  20.  

To install:

  1. Clean and inspect gasket sealing surfaces
    NOTE
    Intake gaskets can be reused, provided they are free of cuts or tears.

  2.  
  3. Inspect gasket for cuts or tears. Replace gaskets as necessary.
  4.  
  5. Install intake manifold and hand start all attaching bolts.

    Click image to see an enlarged view

    Fig. The proper torque sequence

  6.  
  7. Tighten bolts gradually in sequence until a torque of 105 inch lbs. (12 Nm) is obtained
  8.  
  9. Install right and left side intake manifold supports.
  10.  
  11. Install manifold support brackets at front corners and at MTV
  12.  
  13. Tighten fastener attaching throttle body to support bracket.
  14.  
  15. Connect vacuum lines to: Secondary Runner Valve, Speed Control Reservoir, and Positive Crankcase Ventilation (PCV) Valve.
  16.  
  17. Connect electrical connectors to: Intake Air Temperature/Manifold Absolute Pressure (TMAP), Idle Air Control (IAC), Throttle Position Sensor (TPS), and Manifold Tuning Valve (MTV)
  18.  
  19. Install EGR tubes to intake manifold.
  20.  
  21. Install throttle and speed control cables to bracket and throttle arm.
  22.  
  23. Install air cleaner housing and inlet tube.
  24.  
  25. Connect negative cable to remote jumper terminal.
  26.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The intake manifold plenum (upper half of the intake manifold assembly) uses 2 different length bolts. Take note of their position and be sure they are installed in the same location during installation.



    Negative battery cable
     
    Engine cover from the top of the intake manifold
     
    Accelerator and the speed control cable from the throttle lever
     
    Idle Air Control (IAC) motor
     
    Intake Air Temperature (IAT) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Ground screw from the intake manifold
     
    Electrical connector from the Throttle Position (TP) sensor
     
    Vacuum hoses from the manifold tuning valve, Positive Crankcase Ventilation (PCV) make-up air hose, IAC motor supply hose and the purge hose from the throttle bodies
     
    Brake booster hose, PCV hose and the remaining vacuum hoses from the intake manifold
     
    Exhaust Gas Recirculation (EGR) tube-to-intake manifold plenum bolts
     
    Plenum support bracket mounting bolts on each side of the plenum
     
    Intake plenum mounting bolts
     

  8.  
  9. Remove the intake manifold plenum from the intake manifold.
    NOTE
    Discard the old gasket. Cover the intake manifold openings with tape to keep debris from entering the engine.

  10.  
  11. Remove or disconnect the following:
    NOTE
    Clean all gasket mating surfaces and inspect for distortion with a good straightedge.



    Upper radiator hose from the thermostat housing
     
    Heater hose from the rear of the intake manifold
     
    Lower intake manifold bolts and manifold
     



    Click image to see an enlarged view

    Fig. Upper intake manifold loosening and tightening sequence-3.5L engines



    Click image to see an enlarged view

    Fig. Lower intake manifold loosening and tightening sequence-3.5L engines

  12.  

To install:


NOTE
Verify that all intake manifold and cylinder head sealing surfaces are clean.

  1. Install or connect the following:
    NOTE
    Ensure the ignition cables are routed out of the way of the intake plenum.


    NOTE
    Do not overtighten bolts when working with light alloys.


    NOTE
    Be sure that the insulation on the EGR tube aligns with and contacts the insulation on the vacuum harness at the rear of the engine. Rotate the throttle lever to the wide-open position and reconnect the speed control and throttle cables.



    Intake manifold gasket, then the lower manifold. Torque the bolts in the proper sequence to 21 ft. lbs. (28 Nm).
     
    Upper radiator hose to the thermostat housing
     
    Heater hose to the rear of the intake manifold
     



    Intake manifold plenum with a new gasket in place. Torque the mounting bolts, working from the center outward, to 21 ft. lbs. (28 Nm)
     



    Support bracket bolts
     
    Electrical connectors to the MAP sensor, TP sensor, IAC motor and IAT sensor
     
    Vacuum hose to the manifold tuning valve
     
    EGR tube. Torque the EGR tube-to-intake manifold plenum screws to 17 ft. lbs. (22 Nm).
     



    PCV valve hose
     
    Air cleaner plenum and plenum hose
     
    Ground wire to the intake manifold plenum
     
    Brake booster hose to intake manifold plenum fitting
     
    Throttle body purge tubes
     
    Intake manifold plenum cover
     
    Negative battery cable
     

  2.  
  3. Fill and bleed the cooling system.
  4.  
  5. Change the engine oil and filter.
  6.  
  7. Test run the engine, check for fuel and coolant leaks and verify correct engine operation.
  8.  

 
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