Avenger 2008

Intake Manifold

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Removal & Installation



2.4L Engine
  1. Remove engine cover (1).

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    Fig. Remove engine cover (1)

  2.  
  3. Perform fuel system pressure release procedure before attempting any repairs.
  4.  
  5. Remove air cleaner housing (1).

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    Fig. Remove air cleaner housing (1)

  6.  
  7. Disconnect negative battery cable.
  8.  
  9. Disconnect fuel line at rail (3).

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    Fig. Disconnect fuel line at rail (3)

  10.  
  11. Remove fuel injector electrical connectors (4).
  12.  
  13. Remove fuel rail retaining bolts and remove fuel rail.
  14.  
  15. Disconnect oil temperature sensor (1).

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    Fig. Disconnect oil temperature sensor (1)

  16.  
  17. Disconnect variable valve timing solenoid electrical connector.
  18.  
  19. Disconnect intake camshaft position sensor electrical connector.
  20.  
  21. Position harness out of the way.
  22.  
  23. Remove throttle body support bracket (1).

    Click image to see an enlarged view

    Fig. Remove throttle body support bracket (1)

  24.  
  25. Disconnect electronic throttle control electrical connector.
  26.  
  27. Remove wiring harness retainer from the intake manifold (2).
  28.  
  29. Disconnect Manifold Absolute Pressure (MAP) sensor electrical connector.
  30.  
  31. Disconnect vacuum lines at intake.
  32.  
  33. Remove intake manifold retaining bolts.

    Click image to see an enlarged view

    Fig. Remove intake manifold retaining bolts

  34.  
  35. Remove intake manifold.
  36.  

To install:

  1. Clean all gasket surfaces.
  2.  
  3. Replace intake manifold gasket.
  4.  
  5. Install intake manifold, tighten bolts to 220 inch lbs. (25 Nm).
  6.  
  7. Install the fuel rail assembly to intake manifold. Tighten bolts to 200 inch lbs. (23 Nm).
  8.  
  9. Connect fuel injector electrical connectors.
  10.  
  11. Inspect quick connect fittings for damage, replace if necessary.
  12.  
  13. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to make sure it is locked into position.
  14.  
  15. Install air cleaner housing.
  16.  
  17. Connect negative battery cable.
  18.  
  19. Fill the cooling system.
  20.  
  21. Start engine and check for leaks.
  22.  
  23. Install engine cover.
  24.  

2.7L Engine
Lower Manifold

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Release fuel system pressure.
  2.  
  3. Remove upper intake manifold.
  4.  
  5. Disconnect electrical connectors from the fuel injectors.
  6.  
  7. Remove fuel supply hose from fuel rail
  8.  
  9. Remove screw attaching fuel rail support bracket to the throttle body support bracket.
  10.  
  11. Remove bolts attaching fuel rail.
  12.  
  13. Remove fuel rail and injectors as an assembly.

    Click image to see an enlarged view

    Fig. Remove fuel rail and injectors as an assembly

  14.  
  15. Remove manifold attaching bolts.

    Click image to see an enlarged view

    Fig. Remove manifold attaching bolts

  16.  
  17. Remove lower manifold.
  18.  

To install:

  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. 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.

  4.  
  5. Install manifold attaching bolts and tighten in sequence shown, to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Install manifold attaching bolts in sequence

  6.  
  7. Remove bolt used for aligning manifold.
  8.  
  9. Install fuel rail with injectors.
  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. Install screw attaching fuel rail support bracket to the throttle body support bracket.
  14.  
  15. Connect fuel supply hose to fuel rail.
  16.  
  17. Install upper intake manifold.
  18.  

Upper Manifold

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect negative battery cable.
  2.  
  3. Remove throttle body air inlet hose and air cleaner housing assembly.
  4.  
  5. Disconnect electrical connectors from the following components:

    Manifold Absolute Pressure (MAP) sensor
     
    Throttle Position Sensor (TPS)
     
    Idle Air Control (IAC) motor
     
    Inlet Air Temperature (IAT) sensor
     

  6.  
  7. Disconnect vapor purge hose, brake booster hose, Positive Crankcase Ventilation (PCV) hose.
  8.  
  9. Remove EGR tube.
  10.  
  11. Disconnect the Electronic Throttle Control (ETC) (2).

    Click image to see an enlarged view

    Fig. Disconnect the Electronic Throttle Control (ETC) (2)

  12.  
  13. Remove lower throttle body support bracket.
  14.  
  15. Remove rear support bracket fasteners.
  16.  
  17. Remove manifold attaching bolts.
  18.  
  19. Remove upper manifold.
  20.  

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

    Manifold Absolute Pressure (MAP) sensor
     
    Throttle Position Sensor (TPS)
     
    Idle Air Control (IAC) motor
     
    Inlet Air Temperature (IAT) sensor
     

  12.  
  13. Install EGR tube.
  14.  
  15. Connect electronic throttle control connector (ETC).
  16.  
  17. Install throttle body air inlet hose and air cleaner housing assembly.
  18.  
  19. Connect negative battery cable.
  20.  

3.5L Engine
Lower Manifold

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect the negative battery cable.
  2.  
  3. Perform fuel pressure release procedure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the upper radiator hose from the thermostat housing.
  8.  
  9. Remove the upper intake manifold.
  10.  
  11. Disconnect the electrical connectors to fuel injectors and coolant temperature sensor.
  12.  
  13. Disconnect heater supply and return hoses from the thermostat housing.
  14.  
  15. Disconnect the fuel line from the fuel rail.

    Click image to see an enlarged view

    Fig. Disconnect the fuel line from the fuel rail

  16.  
  17. Remove the 4 bolts attaching fuel rail.

    Click image to see an enlarged view

    Fig. Remove the 4 bolts attaching fuel rail

  18.  
  19. Remove fuel rail and injectors as an assembly.
  20.  
  21. Remove lower intake bolts and position the ignition coil capacitor aside.

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    Fig. Position the ignition coil capacitor aside

  22.  
  23. Remove the lower intake manifold (1).

    Click image to see an enlarged view

    Fig. Remove the lower intake manifold (1)

  24.  

To install:

  1. Clean all sealing surfaces.
  2.  
  3. Position new gaskets and intake manifold on cylinder head surfaces.
  4.  
  5. Position the ignition coil capacitor and install the intake manifold bolts. Gradually tighten in sequence shown until a torque of 21 ft. lbs. (28 Nm) is obtained.

    Click image to see an enlarged view

    Fig. Install the intake manifold bolts in sequence

  6.  
  7. Install fuel rail and injectors as an assembly.
  8.  
  9. Connect fuel supply hose to fuel rail.
  10.  
  11. Connect heater supply and return hoses to the intake manifold.
  12.  
  13. Connect electrical connectors to fuel injectors and coolant temperature sensor.
  14.  
  15. Install upper intake manifold.
  16.  
  17. Connect the upper radiator hose to the thermostat housing.
  18.  
  19. Fill the cooling system.
  20.  
  21. Connect negative battery cable.
  22.  

Upper Manifold

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove engine cover.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove air cleaner housing and inlet hose.

    Click image to see an enlarged view

    Fig. Remove air cleaner housing and inlet hose

    1. Remove the air inlet hose at the throttle body (1).
    2.  
    3. Disconnect the Intake Air Temperature (IAT) sensor wiring harness connector (2).
    4.  
    5. Disconnect the air circulation hose at the element housing (5).
    6.  
    7. Remove the housing retaining bolt (4).
    8.  
    9. Pull housing up and off of the locating pin.
    10.  
    11. Remove element housing from vehicle.
    12.  

  6.  
  7. Disconnect the EGR tube.

    Click image to see an enlarged view

    Fig. Disconnect the EGR tube

    1. Disconnect and isolate negative battery cable at battery.
    2.  
    3. Remove EGR tube bolts (3) at Exhaust Gas Recirculation (EGR) valve (2).
    4.  
    5. Remove EGR tube (4) from EGR valve (2).
    6.  
    7. Remove and discard gasket (5) located between EGR valve (2) and EGR tube (4).
    8.  
    9. Disconnect electrical connector at EGR valve (2).
    10.  
    11. Remove EGR valve mounting bolts (6).
    12.  
    13. Remove EGR valve (2) from cylinder head (1).
    14.  
    15. Remove and discard gasket located between EGR valve (2) and cylinder head (1).
    16.  

  8.  
  9. Disconnect the following vacuum hoses from the upper intake manifold:

    Click image to see an enlarged view

    Fig. Disconnect the vacuum hoses from the upper intake manifold



    Positive Crankcase Ventilation (PCV) Valve (1)
     
    EVAP Purge Solenoid (2)
     
    EGR Tube (3)
     
    Power Brake Booster (4)
     

  10.  
  11. Disconnect electrical connectors from the following sensors and actuators:

    Click image to see an enlarged view

    Fig. Disconnect electrical connectors from the sensors and actuators



    Manifold Tuning Valve (MTV) (1)
     
    Short Runner Valve (2)
     
    Throttle Position Sensor (TPS) (3)
     
    Manifold Absolute Pressure (MAP) (4)
     

  12.  
  13. Remove the Manifold Tuning Valve (5), then remove the 2 nuts (1) and (2) from the rear intake manifold brackets.

    Click image to see an enlarged view

    Fig. Remove the Manifold Tuning Valve (5)

  14.  
  15. Loosen the 2 bolts (3) and (4) from rear intake manifold brackets and position brackets aside.
  16.  
  17. Remove the 7 upper intake manifold retaining bolts (1) and the upper intake manifold (2).

    Click image to see an enlarged view

    Fig. Remove the 7 upper intake manifold retaining bolts (1) and the upper intake manifold (2)

  18.  

To install:

  1. Clean and inspect gasket sealing surfaces.
  2.  
  3. Position new gasket.
  4.  
  5. Install the throttle body on the upper intake (if required).
  6.  
  7. Install upper intake manifold and hand start all attaching bolts.
  8.  
  9. Tighten bolts gradually starting in the center working outward until a torque of 105 inch lbs. (12 Nm) is obtained.
  10.  
  11. Install the rear intake manifold brackets to the head.
  12.  
  13. Install the 2 intake manifold to bracket nut retainers.
  14.  
  15. Install the EGR tube.
  16.  
  17. Connect electrical connectors to the following sensors and actuators:

    Manifold Tuning Valve (MTV)
     
    Short Runner Valve
     
    Throttle Position Sensor (TPS)
     
    Manifold Absolute Pressure (MAP)
     

  18.  
  19. Connect the following vacuum hoses to the upper intake manifold:

    Positive Crankcase Ventilation (PCV) Valve
     
    EVAP Purge Solenoid
     
    EGR Tube
     
    Power Brake Booster
     

  20.  
  21. Install air cleaner housing and inlet hose.
  22.  
  23. Connect negative battery cable.
  24.  
  25. Install the engine cover.
  26.  

 
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