Chrysler Concorde/Intrepid/LHS/New Yorker/Vision 1993-1997

Intake Manifold

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REMOVAL & INSTALLATION



3.3L Engine

See Figures 1 through 20

The intake manifold is a tuned two-piece aluminum casting with individual primary runners running from a plenum (the upper part of the manifold). The intake manifold assembly is cored with upper level EGR passages for balanced cylinder-to cylinder EGR distribution. These openings should be inspected and cleaned if necessary whenever the manifold is removed for service. Use care when working with light alloy parts. Do not over-tighten any fasteners or the casting may be damaged.

  1. Disconnect negative battery cable.
  2.  
  3. Remove the fuel filler cap. Release the fuel system pressure using the recommended procedure.
  4.  

  1. Drain the cooling system.
  2.  
  3. Disconnect the air tube from the air cleaner and the throttle body.
  4.  
  5. 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 from the mounting brackets.
  6.  



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Fig. Fig. 1: Compress the locking tabs on the throttle and cruise control cables and remove them

  1. Unplug the electrical connector from the solenoid on the EGR valve transducer, MAP sensor, throttle position sensor and the idle air control motor.
  2.  



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Fig. Fig. 2: Disconnect the solenoid from the EGR transducer



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Fig. Fig. 3: Label and remove any vacuum hoses attached to the intake manifold

  1. Disconnect the vacuum hose from the PCV valve as well as the power brake booster at the intake manifold nipple. Disconnect the vacuum line at the fuel pressure regulator.
  2.  



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Fig. Fig. 4: Disconnect the electrical harness leading to the MAP sensor



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Fig. Fig. 5: Disconnect the vacuum hose from the PCV valve

  1. Disconnect the purge hose from the throttle body.
  2.  
  3. Unplug the electrical harnesses from the throttle position sensor and the idle air control motor.
  4.  



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Fig. Fig. 6: The throttle position sensor is located on the side of the throttle body, disconnect it

  1. Remove the EGR tube mounting screws at the intake manifold plenum.
  2.  



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Fig. Fig. 7: Unscrew the EGR mounting tube at the intake plenum

  1. Remove the intake manifold plenum (upper part of the manifold) mounting bolts and remove the plenum from the engine. Cover the lower part of the intake manifold to prevent foreign material from entering the engine.
  2.  



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Fig. Fig. 8: Remove the intake manifold plenum mounting bolts



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Fig. Fig. 9: Double check everything is detached, then lift the plenum off the lower manifold



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Fig. Fig. 10: Fill the lower intake openings with clean rags

  1. Disconnect the fuel supply and return tubes to the fuel rail at the rear of the intake manifold 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.
  2.  



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Fig. Fig. 11: Disconnect the fuel supply and return tube quick-connect fittings art the rear of the manifold

  1. Cover the fuel line openings to prevent system contamination.
  2.  
  3. Remove the screw from the fuel clamp and separate the fuel tubes from the bracket.
  4.  



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Fig. Fig. 12: Remove the fuel rail mounting bolts

  1. Tag each connector for identification, then disconnect the electrical harness from the injectors and turn toward the center of the engine.
  2.  
  3. Remove the fuel rail mounting bolts and lift fuel rail with the injectors attached straight up and off the engine. Cover the injector openings.
  4.  
  5. Remove the upper radiator hose, heater hose and the rear intake manifold hose.
  6.  



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Fig. Fig. 13: Loosening and tightening sequence for the intake manifold bolts-3.3L engine

  1. Remove the intake manifold bolts and the manifold from the engine.
  2.  



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Fig. Fig. 14: Remove the intake manifold bolts ...



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Fig. Fig. 15: ... then lift the manifold from the engine carefully

  1. Remove the intake manifold seal retainers screws and remove the intake manifold gasket. Clean all mating surfaces.
  2.  



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Fig. Fig. 16: The intake manifold gasket cannot be removed until the retainers are removed



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Fig. Fig. 17: The retainers are held in by screws on the ends of the block



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Fig. Fig. 18: Now you can easily lift the intake gasket off the engine block

  1. Inspect the manifold for damage, cracks or clogged passages. Repair, clean or replace the manifold as required.
  2.  

To install:
  1. Verify that all intake manifold and cylinder head sealing surfaces are clean. Place a drop of sealant onto each of the four corners of the intake manifold gasket, where the cylinder head meets the engine block. Carefully install the intake manifold gasket and tighten the seal retainers to 105 inch lbs. (12 Nm).
  2.  



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Fig. Fig. 19: Apply a bead of sealant on each of the four corners of the intake seating

The intake manifold gasket is made of very thin metal and can cause cuts if handled carelessly.

  1. Install the intake manifold and eight mounting bolts. Snug down evenly to just 10 inch lbs. (1 Nm).
  2.  
  3. Tighten intake manifold bolts in the proper sequence to 16 ft. lbs. (22 Nm). Once all bolts are tightened, repeat the sequence again tightening the bolts to 16 ft. lbs. (22 Nm). Inspect to make sure all seals are still in place.
  4.  
  5. Apply a light coat of clean engine oil to the O-ring on the nozzle end of each injector.
  6.  
  7. Insert the fuel injector nozzles into the openings in the intake manifold. Seat the injectors in place and install the fuel rail mounting bolts, tightening to 16 ft. lbs. (22 Nm).
  8.  
  9. Attach the electrical connectors to each fuel injector. Rotate the injectors toward the cylinder head covers.
  10.  
  11. Reconnect the 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.
  12.  
  13. 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.
  14.  
  15. Install the intake plenum with new gasket onto the intake manifold. Loosely install the mounting bolts.
  16.  



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Fig. Fig. 20: Tightening sequence for the intake plenum-3.3L engine

  1. Install the EGR tube to the manifold with new gasket in place. Loosely install the mounting screws.
  2.  
  3. Tighten the intake manifold plenum mounting bolts to 21 ft. lbs. (28 Nm) following the outlined sequence.
  4.  
  5. Tighten the EGR tube mounting bolts.
  6.  
  7. Reconnect the PCV valve hose and power brake booster hose.
  8.  
  9. Attach the electrical connectors to the EGR transducer solenoid, idle air control motor, map and throttle position sensors.
  10.  
  11. Install the 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.
  12.  
  13. Reconnect the purge hose to the throttle body. Reconnect the air tube to the air cleaner and the throttle body.
  14.  
  15. Drain and replace the engine oil and oil filter.
  16.  
  17. Reconnect the negative battery cable. Refill 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.
  18.  
  19. Once the vehicle has cooled, recheck the coolant level and add, if necessary.
  20.  

3.5L Engine

See Figures 21, 22, 23, 24, 25, 26, 27, 28 and 29

The intake manifold is a two-piece aluminum casting and is a cross-flow type with long runners to improve intake mixture inertia. The upper half of the manifold assembly is called a plenum. The air plenum chambers absorb air pulses created during the suction phase of each cylinder. A Manifold Tuning Valve (MTV) connects the plenums at specific engine speeds to maximize low rpm torque without reducing high rpm power. Use care when working with light alloy components. Do not overtighten fasteners or the casting could be damaged.

  1. Disconnect negative battery cable.
  2.  
  3. Remove the fuel filler cap. Release the fuel system pressure using the recommended procedure.
  4.  

  1. Drain the cooling system.
  2.  
  3. Remove the engine cover from the top of the intake manifold.
  4.  
  5. Remove the accelerator and the speed control cable from the throttle lever.
  6.  



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Fig. Fig. 21: Remove the accelerator and speed control cables from the throttle arm

  1. Unplug the electrical connector from the idle air control motor, intake air temperature sensor and the Manifold Absolute Pressure (MAP) sensor.
  2.  



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Fig. Fig. 22: Disconnect the vacuum hose from the Manifold Tuning Valve (MTV)



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Fig. Fig. 23: Separate the connection to the MAP sensor

  1. Remove the ground screw from the intake manifold. Unplug the electrical connector to the throttle position sensor.
  2.  



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Fig. Fig. 24: Disconnect the throttle position sensor

  1. Disconnect the vacuum hoses from the manifold tuning valve, PCV make-up air hose, idle air control motor supply hose and the purge hose from the throttle bodies.
  2.  
  3. Disconnect the brake booster hose, PCV hose and the remaining vacuum hoses from the intake manifold. If required, label for proper installation.
  4.  
  5. Remove the mounting bolts for the EGR tube at the intake manifold plenum.
  6.  
  7. Remove the plenum support bracket mounting bolts on each side of the plenum. Remove the intake plenum mounting bolts.
  8.  



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Fig. Fig. 25: Remove the air inlet from the plenum

The intake manifold plenum (upper half of the intake manifold assembly) uses two different length bolts. Take note of their position and make sure they are installed in the same location during installation.



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Fig. Fig. 26: Unbolt the EGR tube at the plenum



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Fig. Fig. 27: Remove the air plenum support bracket bolt on each side of the manifold



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Fig. Fig. 28: Remove the four plenum bolts, they are two different sizes

  1. Remove the intake manifold plenum from the intake manifold. Discard the old gasket. Cover the intake manifold openings with tape to keep debris from entering the engine.
  2.  
  3. Remove the upper radiator hose from the thermostat housing and the heater hose from the rear of the intake manifold.
  4.  
  5. Remove the lower intake manifold retaining bolts and the manifold from the engine. Clean all gasket mating surfaces and inspect for distortion with a good straightedge.
  6.  



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Fig. Fig. 29: Loosening and tightening sequence for the manifold bolts-3.5L engine

To install:
  1. Verify that all intake manifold and cylinder head sealing surfaces are clean. Carefully install the intake manifold gasket, then the lower manifold. Tighten bolts in proper sequence to 250 inch lbs. (28 Nm).
  2.  
  3. Reconnect the upper radiator hose to the thermostat housing and the heater hose to the rear of the intake manifold.
  4.  
  5. Ensure the ignition cables are routed out of the way of the intake plenum. Install the intake manifold plenum with new gasket in place and tighten in sequence to 250 inch lbs. (28 Nm).
  6.  
  7. Install the intake manifold plenum with a new gasket in place. Tighten mounting bolts working from the center outward, to 250 inch lbs. (28 Nm). Do not overtighten bolts when working with light alloys.
  8.  
  9. Install and tighten the support bracket bolts.
  10.  
  11. Reconnect the electrical connectors to the manifold absolute pressure sensor, throttle position sensor, idle air control motor and intake air temperature sensor.
  12.  
  13. Reconnect the vacuum hose to the manifold tuning valve.
  14.  
  15. Install the EGR tube. Tighten the EGR tube to intake manifold plenum screws to 200 inch lbs. (22 Nm). Make 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.
  16.  
  17. Reconnect the PCV valve hose. Install the air cleaner plenum and reconnect plenum hose.
  18.  
  19. Reconnect the ground wire the the intake manifold plenum. Reconnect the brake booster hose to the fitting on the intake manifold plenum.
  20.  
  21. Reconnect the throttle body purge tubes.
  22.  
  23. Install the cover on the intake manifold plenum.
  24.  
  25. Reconnect the negative battery cable. Fill and bleed the cooling system.
  26.  
  27. Raise and safely support the vehicle. Change the engine oil and filter.
  28.  
  29. Test run the engine, check for fuel and coolant leaks and verify correct engine operation.
  30.  

 
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