Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Intake Manifold

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REMOVAL & INSTALLATION



2.0L SOHC and 2.4L DOHC Engines

See Figures 1, 2 and 3

The intake manifold for the 2.0L SOHC engine is a long branch design made of a molded plastic composition. It is attached to the cylinder head with 10 fasteners. Please note that all seals are to be replaced with new seals and all fasteners are to be replaced with new fasteners. Obtain the necessary parts before beginning work.

The intake manifold for the 2.4L DOHC engine is a long branch design made of cast aluminum. It is attached to the cylinder head with 8 fasteners.

  1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. The fuel system pressure MUST be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Properly relieve the fuel system pressure using the procedure outlined in Fuel System .
  2.  
  3. Remove the air inlet resonator as follows:
    1. On the 2.4L DOHC engine only, remove the 2 mounting bolts that secure the air inlet resonator to the intake manifold.
    2.  
    3. Loosen the screw securing the air inlet resonator to the throttle body.
    4.  
    5. Loosen the clamp securing the air inlet resonator to the air inlet tube. Remove the resonator.
    6.  

  4.  
  5. Disconnect the fuel supply line quick-connect fitting from the fuel rail by squeezing the retainer tabs together and pulling the fuel tube/quick-connect fitting from the fuel tube nipple. The retainer will remain on the fuel tube. Wrap shop towels around the fuel line openings to catch any spilling fuel.
  6.  
  7. Remove the fuel rail attaching screws and remove the fuel rail. Use care when handling the fuel injectors. Do not set them on their tips. Cover the fuel injector openings after fuel rail removal.
  8.  
  9. Remove the accelerator, kickdown and speed control cables from the throttle lever and bracket.
  10.  
  11. Disengage the Throttle Position Sensor (TPS) and the Idle Air Control (IAC) motor electrical connections.
  12.  
  13. Disconnect the vacuum hoses from the throttle body.
  14.  
  15. Disengage the connectors from the Manifold Absolute Pressure (MAP) sensor and the intake air temperature sensors.
  16.  
  17. Disconnect the vapor and brake booster hoses.
  18.  
  19. Disengage the knock sensor electrical connector, starter relay connector (if necessary), and the wiring harness from the tab located on the intake manifold.
  20.  
  21. Remove the transaxle to throttle body support bracket fasteners at the throttle body and loosen the fastener at the transaxle end.
  22.  
  23. Remove the throttle body assembly as outlined in Fuel System .
  24.  
  25. Remove the EGR tube bolts at the valve and at the intake manifold. Remove the tube from the engine.
  26.  
  27. Remove the intake manifold-to-inlet water tube support fastener (2.0L) or intake manifold support bracket (2.4L).
  28.  
  29. Remove the intake manifold fasteners and washer assemblies. On the 2.0L engine, discard the fasteners and, during assembly, replace them with new fasteners.
  30.  
  31. Remove the intake manifold from the vehicle.
  32.  

To install:
  1. Clean all gasket sealing surfaces. Check the upper and lower manifold gasket surfaces for cracks or distortion.
  2.  



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Fig. Fig. 1: Make sure that the intake manifold O-ring gaskets are properly seated-2.0L SOHC engine



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Fig. Fig. 2: Intake manifold tightening sequence-2.0L SOHC engine



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Fig. Fig. 3: Intake manifold tightening sequence-2.4L DOHC engine

  1. For the 2.0L engine, install the intake manifold with new O-ring seals. For the 2.4L engine, install a new intake manifold gasket and position the manifold on the cylinder head. Tighten the fasteners to 105 inch lbs. (12 Nm) in correct sequence, starting from the center and working outward.
  2.  
  3. Remove the covers from the fuel injector openings and install the fuel injectors into the engine. Seat the injectors in place and tighten the fuel rail bolts to 200 inch lbs. (23 Nm).
  4.  
  5. Connect the PCV and brake booster hoses.
  6.  
  7. Inspect the quick-connect fittings for damage and repair as required. Lubricate the fuel line with clean 30W engine oil. Reconnect the fuel supply line hose to the fuel rail assembly. Check the connection by pulling on the connector to insure it is locked in position.
  8.  
  9. Engage the electrical connectors to the fuel injectors.
  10.  
  11. Install the throttle body and tighten to 200 inch lbs. (23 Nm). Reinstall the transaxle to throttle body support bracket and tighten to 105 inch lbs. (12 Nm) at the throttle body first. Next, tighten the bracket at the transaxle.
  12.  
  13. Engage the MAP sensor and the air temperature sensor wiring connectors.
  14.  
  15. Engage the knock sensor electrical and starter relay connectors. Reconnect the wiring harness to the intake manifold tab.
  16.  
  17. Engage the IAC and TPS wiring connectors.
  18.  
  19. Reconnect the throttle body vacuum hoses.
  20.  
  21. Install the accelerator, kickdown and speed control cables to their bracket, then connect them to the throttle lever.
  22.  
  23. Loosely assemble the EGR tube onto the valve and intake manifold finger-tight. Tighten the tube fasteners at the EGR valve first to 95 inch lbs. (11 Nm), then tighten the intake manifold side fasteners to 95 inch lbs. (11 Nm).
  24.  
  25. Install the air inlet resonator to the throttle body. Connect the air inlet tube to the resonator and tighten the clamps to 20-30 inch lbs. (2-3 Nm).
  26.  
  27. Connect the negative battery cable. Pressurize the fuel system using the DRB Scan Tool, or equivalent. Perform the ASD Fuel System Test and check for leaks.
  28.  

2.0L DOHC Engine

See Figure 4

This engine uses a two-piece aluminum intake manifold. The upper half of the manifold (also called a plenum) mounts the throttle body. The lower half of the manifold contains the fuel rail and injectors. A non-reusable gasket joins the two halves. Use care when working with light alloy parts.


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable and drain the cooling system.
  4.  
  5. Disconnect the accelerator cable, breather hose and air intake hose.
  6.  
  7. Disengage the vacuum connection at the power brake booster and the PCV valve. Disconnect all remaining vacuum hoses and pipes, as necessary. Tag for identification, if necessary, to save time at assembly.
  8.  
  9. Disconnect the fuel line(s), then remove the throttle control cable and brackets.
  10.  


CAUTION
Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only hoses and clamps specifically designed for fuel injection.

  1. Unplug the alternator wiring harness connection.
  2.  
  3. Disengage the MAP sensor and the intake air temperature sensor connectors.
  4.  
  5. Disengage the TPS connector and position the engine wiring harness aside.
  6.  
  7. Disengage the EGR pipe connection.
  8.  
  9. Remove the intake manifold stay and the engine hanger. Disengage the fuel injector connectors.
  10.  
  11. Remove the throttle body assembly as outlined in Fuel System .
  12.  
  13. Unfasten the mounting bolts and remove the intake manifold plenum and gasket.
  14.  
  15. Remove the complete fuel rail assembly. Use care since the fuel injectors can drop out of the fuel rail as it is being removed.
  16.  
  17. Remove the mounting bolts, then remove the intake manifold and gasket from the engine.
  18.  



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Fig. Fig. 4: Intake manifold assembly-2.0L DOHC engine

To install:
  1. Clean all gasket material from the cylinder head and intake manifold assembly. Check both surfaces for cracks or other damage. Check the intake manifold water passages and air passages for clogging. Clean if necessary. Check the gasket surface of the intake manifold for flatness using a straightedge and feeler gauge. It should be 0.006 inch (0.152mm) or less. The limit is 0.008 inch (0.203mm).
  2.  
  3. Install a new intake manifold gasket to the cylinder head and install the manifold. Tighten the manifold in a crisscross pattern, starting from the inside and working outwards to 17 ft. lbs. (23 Nm).
  4.  
  5. Apply a thin coat of clean engine oil to the fuel injector O-rings. Install the fuel rail, injector and pressure regulator assembly to the lower intake manifold.
  6.  
  7. Thoroughly clean the mating surfaces and install the intake manifold plenum with a new gasket.
  8.  
  9. Install the throttle body assembly.
  10.  
  11. Install the intake manifold stay and the engine hanger. Plug in the fuel injector connectors.
  12.  
  13. Attach the EGR pipe connection.
  14.  
  15. Engage the engine control electrical connectors.
  16.  
  17. Engage the alternator wiring harness connection.
  18.  
  19. Connect the fuel line(s) and the throttle control cable brackets.
  20.  
  21. Connect the vacuum hose at the power brake booster and the PCV valve. Connect all remaining vacuum hoses and pipes.
  22.  
  23. Connect the accelerator cable, breather hose and air intake hose.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Start the engine and check for proper operation.
  28.  

2.5L Engine

See Figures 5 through 17

  1. Disconnect the negative battery cable. On Sebring convertible, Cirrus, Stratus and Breeze models, disconnect the negative battery cable from the left strut tower. The ground cable is equipped with an insulator grommet, which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
  2.  
  3. Properly relieve the fuel system pressure using the procedure outlined in Fuel System .
  4.  


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure MUST be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Disconnect the fuel line(s) from the fuel rail assembly. On quick-connect fittings, squeeze the fitting retainer tabs together and separate the connection.
  2.  


CAUTION
Wrap shop towels around the connection to catch any gasoline spillage.

  1. Loosen the throttle body air inlet hose clamp, then release the snaps holding the air cleaner housing cover to the housing. Remove the air cleaner cover and inlet hose from the engine.
  2.  
  3. Unplug the vacuum connection at the power brake booster and the PCV valve. Disconnect all remaining vacuum hoses and pipes, as necessary. Tag for identification, if necessary, to save time at assembly.
  4.  

It may be helpful to identify and tag each sensor connector and vacuum connection as it is being removed or disengaged. This may save time at assembly.

  1. Disengage the connectors from the Manifold Absolute Pressure (MAP) sensor and the intake air temperature sensors.
  2.  
  3. If necessary, disengage the power steering pressure switch and oxygen sensor connectors.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Remove the right side intake manifold plenum support bracket bolt

  1. Remove the plenum support bracket located to the rear of the MAP sensor.
  2.  
  3. On all models except Sebring and Avenger coupes, loosen the attaching bolt, then remove the air inlet resonator. This is located on top of the engine intake manifold plenum.
  4.  
  5. On Sebring and Avenger coupes, remove the control wiring harness mounting fasteners located on top of the upper plenum near the valve cover.
  6.  
  7. Disconnect the Throttle Position Sensor (TPS) and the Idle Air Control (IAC) motor electrical connections.
  8.  
  9. Remove the throttle body assembly as outlined in Fuel System .
  10.  
  11. Remove the throttle cable bracket.
  12.  
  13. Remove the EGR tube from the engine intake manifold.
  14.  
  15. On Sebring and Avenger coupes, remove the EGR valve and transducer assembly.
  16.  



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Fig. Fig. 6: Remove the left side intake manifold plenum support bracket bolt



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Fig. Fig. 7: Remove the intake manifold plenum mounting bolts



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Fig. Fig. 8: Remove the intake manifold plenum from the engine



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Fig. Fig. 9: Remove the intake plenum-to-lower intake manifold gasket

  1. Remove the plenum support bracket located to the rear of the EGR tube.
  2.  
  3. Remove the 7 bolts attaching the upper intake plenum to the lower manifold, and remove the plenum. Remove the intake plenum-to-lower manifold gasket.
  4.  
  5. Detach the fuel injector electrical connectors.
  6.  
  7. Remove the 4 bolts attaching the fuel rail to the intake manifold.
  8.  

There are spacers under each fuel rail bolt.

  1. Remove the fuel rail, using care not to lose the spacers.
  2.  



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Fig. Fig. 10: Loosen the power steering fluid reservoir mounting bracket bolts ...



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Fig. Fig. 11: ... then remove the reservoir bracket from the engine



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Fig. Fig. 12: There is a "hidden" intake manifold mounting bolt on the timing belt side that must be removed

It may be necessary to remove the power steering fluid reservoir and mounting bracket to access all of the lower intake manifold fasteners.

  1. Remove the lower intake manifold attaching bolts.
  2.  
  3. Remove the intake manifold and discard the old gaskets.
  4.  



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Fig. Fig. 13: Remove the intake manifold mounting fasteners



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Fig. Fig. 14: Be careful not to lose the mounting fasteners and washers



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Fig. Fig. 15: Disconnect the vacuum hose from the intake manifold



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Fig. Fig. 16: Lift the intake manifold up and off of the engine



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Fig. Fig. 17: Remove the intake manifold gaskets from the engine

To install:
  1. Clean all gasket sealing surfaces. Check both surfaces for cracks or other damage. Check the intake manifold air passages for clogging. Clean if necessary.
  2.  
  3. Check the upper and lower manifold gasket surfaces for flatness using a straightedge and feeler gauge.
  4.  
  5. Surface must be flat within 0.006 inch (0.152mm) per 12 inches (30.48cm) of manifold length. The limit is 0.008 inch (0.203mm).
  6.  
  7. Properly position the new gaskets to the heads and install the lower intake manifold. Tighten the manifold in correct sequence, as illustrated following this procedure.
    1. Tighten the nuts in the front bank to 5 ft. lbs. (7 Nm).
    2.  
    3. Tighten the nuts in the rear bank to 14 to 17 ft. lbs. (20 to 23 Nm).
    4.  
    5. Tighten the nuts in the front bank to 14 to 17 ft. lbs. (20 to 23 Nm).
    6.  
    7. Repeat Steps b and c again.
    8.  

  8.  
  9. Apply a light coating of engine oil to the fuel injector O-rings.
  10.  
  11. Reinstall the fuel injectors into the engine.
  12.  
  13. Seat the injectors in place and tighten the fuel rail bolts to 8 ft. lbs. (12 Nm).
  14.  
  15. Engage the electrical connectors to the fuel injectors.
  16.  
  17. Reconnect the fuel line(s) to the fuel rail assembly. Exert a slight tug on the fuel line away from the fuel rail to verify positive engagement.
  18.  
  19. Install the upper intake plenum with new gaskets.
  20.  
  21. Tighten the plenum bolts to 13 ft. lbs. (18 Nm).
  22.  
  23. Reinstall the plenum support brackets and tighten to 13 ft. lbs. (18 Nm).
  24.  
  25. On Sebring and Avenger coupes, install the EGR valve and transducer assembly.
  26.  
  27. Install the EGR tube and tighten the screws to 95 inch lbs. (11 Nm).
  28.  
  29. Install the throttle cable bracket.
  30.  
  31. Install the throttle body assembly as outlined in Fuel System .
  32.  
  33. Reconnect the TPS and IAC electrical connections.
  34.  
  35. On all models except Sebring and Avenger coupes, install the air inlet resonator and tighten the attaching bolt.
  36.  
  37. On Sebring and Avenger coupes, place the control wiring harness into correct position on the engine and tighten the mounting fasteners.
  38.  
  39. Engage the power steering pressure switch and oxygen sensor connectors, if previously disconnected.
  40.  
  41. Engage the MAP sensor and the intake air temperature sensor connectors.
  42.  
  43. Connect the vacuum hose at the power brake booster and the PCV valve. Connect all remaining vacuum hoses and pipes.
  44.  
  45. Connect the remaining engine control system electrical connectors.
  46.  
  47. Reinstall the air cleaner cover and air inlet hose. Tighten the intake hose-to-throttle body hose clamp.
  48.  
  49. Reconnect the negative battery cable.
  50.  
  51. Start the engine and check for leaks.
  52.  

 
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