Chrysler Neon 1995-1999 Repair Guide

Intake Manifold

Print

REMOVAL & INSTALLATION



SOHC Engine

See Figures 1 through 14

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fresh air inlet duct from the air cleaner.
  4.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Properly relieve the fuel system pressure, as outlined in Fuel System .
  2.  
  3. Remove the throttle body, as outlined in Fuel System of this guide.
  4.  
  5. Remove the clean air duct and upper air filter housing.
  6.  
  7. Wrap towels around the fitting to catch any spilled fuel, then disconnect the fuel supply line quick-connect from the fuel tube assembly.
  8.  
  9. Unfasten the fuel rail attaching screws, then remove the fuel rail from the engine. Make sure to cover the injector openings.
  10.  


WARNING
Do NOT set the fuel injectors on their tips, as this may damage them.



Click image to see an enlarged view

Fig. Fig. 1: Remove the fuel rail, and place clean rags in the injector openings to prevent debris from entering them.

  1. Detach the electrical connector(s) from the MAP and IAT sensors. On early models there are 2 sensors, on later models they are combined into 1 sensor.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Unplug the MAP sensor (1) and IAT sensor (2) electrical connectors

  1. Unplug the knock sensor electrical connector.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Detach the knock sensor electrical connector

  1. Disconnect the wiring from the starter, then unclip the wiring harness and position it out of the way.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: After unfastening the starter relay connector, unclip the wiring harness and position it aside

  1. Remove the EGR tube bolts at the intake manifold, then remove the tube from the manifold. Remove the gasket.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Unfasten the EGR tube-to-intake manifold bolts ...



Click image to see an enlarged view

Fig. Fig. 6: ... then separate the tube and remove the gasket

  1. Disconnect the brake booster vacuum hose.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: Use a pair of needle nose pliers to unfasten the hose clamp ...



Click image to see an enlarged view

Fig. Fig. 8: ... then disconnect the brake booster vacuum hose

  1. Disconnect the PCV vapor hose.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Disconnect the PCV vapor hose

  1. Unfasten the intake manifold-to-inlet water tube support fastener.
  2.  



Click image to see an enlarged view

Fig. Fig. 10: Remove the intake manifold-to-inlet water tube support fastener

  1. Remove and discard the intake manifold retainers. Remove the intake manifold from the vehicle.
  2.  



Click image to see an enlarged view

Fig. Fig. 11: Remove and discard the intake manifold retaining bolts and studs ...



Click image to see an enlarged view

Fig. Fig. 12: ... then remove the intake manifold from the vehicle

  1. Remove and discard the gaskets and seals. Thoroughly clean the gasket mating surfaces.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Remove the gaskets and seals and replace with new ones during installation

To install:
  1. Position new gaskets and seals, then install the intake manifold. Install new retainers and tighten them in the sequence shown in the accompanying figure to 9 ft. lbs. (16 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Intake manifold retainer tightening sequence-SOHC engines

  1. Install the intake manifold-to-water inlet support fastener and tighten to 9 ft. lbs. (16 Nm).
  2.  
  3. Remove the covering from the fuel injector holes and make sure the holes are clean. Install the fuel rail assembly to the intake manifold and tighten the screws to 17 ft. lbs. (23 Nm).
  4.  
  5. Connect the PCV and brake booster vacuum hoses.
  6.  
  7. Inspect the fuel line quick-connect fittings for damage and replace if necessary. Apply a small amount of clean engine oil to the fuel inlet tube. Connect the fuel supply hose to the fuel rail assembly. Check to be sure the connection is fastened securely by pulling on the connector.
  8.  
  9. Install the throttle body. Tighten the fastener to 16 ft. lbs. (22 Nm). Install the transmission-to-throttle body support bracket and tighten to 9 ft. lbs. (16 Nm) at the throttle body first. Next, tighten the bracket at the transmission.
  10.  
  11. Attach the MAP and IAT electrical connector(s).
  12.  
  13. Connect the knock sensor wiring and the wiring at the starter. Fasten the wiring harness to the intake manifold tab.
  14.  
  15. Attach the Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
  16.  
  17. Connect the vacuum hoses to the throttle body.
  18.  
  19. Install accelerator, kickdown and speed control cables to their bracket and connect them to the throttle lever.
  20.  
  21. Loosely assemble the EGR tube to the intake manifold finger-tight, then tighten the retainers to 95 inch lbs. (11 Nm).
  22.  
  23. Install the clean air duct to the air filter housing, then tighten the clamp to 30 inch lbs. (3 Nm).
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Attach the fresh air duct to the air cleaner and tighten the wing nut securely.
  28.  

DOHC Engine

See Figures 15, 16 and 17

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the wing nut on the intake, then remove the fresh air inlet duct.
  4.  



Click image to see an enlarged view

Fig. Fig. 15: The fresh air inlet duct is secured with a wing nut

  1. Properly relieve the fuel system pressure, as outlined in Fuel System of this guide.
  2.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Wrap towels around the fitting to catch any spilled fuel, then disconnect the fuel supply line quick-connect from the fuel tube assembly.
  2.  
  3. Remove the clean air inlet duct.
  4.  
  5. Detach the coolant temperature sensor electrical connector.
  6.  
  7. Disconnect the heater hose from the intake manifold and the heater tube from the bottom of the intake manifold.
  8.  
  9. Disconnect the upper radiator and coolant recovery hoses.
  10.  


WARNING
Do not allow the injectors to rest on their tips, as this may cause damage.

  1. Unfasten the attaching screws, then remove the fuel rail from the engine. Cover the injector openings with a suitable covering to prevent debris from entering the ports.
  2.  
  3. Remove the accelerator, kickdown and speed control (if equipped) cables from the throttle lever and bracket.
  4.  
  5. Detach the Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
  6.  
  7. Tag and disconnect the vacuum hoses from the throttle body, then remove the throttle body from the vehicle.
  8.  
  9. Detach the Manifold Absolute Pressure (MAP) and Intake Air Temperature (IAT) sensor electrical connector. Disconnect the vapor and brake booster hoses.
  10.  
  11. Detach the knock sensor electrical connector and disconnect the wiring harness from the tab located on the heater tube.
  12.  
  13. Disconnect the wiring from the starter.
  14.  
  15. Unfasten the EGR tube bolts at the valve and at the intake manifold. Remove the tube from the engine.
  16.  
  17. Remove the intake manifold fasteners, then remove the upper and lower intake manifold assemblies. If necessary, you can separate the upper and lower manifolds.
  18.  
  19. Remove and discard the gaskets, then thoroughly clean all of the gasket mating surfaces.
  20.  

To install:
  1. If separated, position a new gasket, then assemble the lower manifold to the upper, then tighten the retaining bolts to 21 ft. lbs. (28 Nm) in the sequence shown in the accompanying figure.
  2.  



Click image to see an enlarged view

Fig. Fig. 16: Lower-to-upper intake manifold bolt tightening sequence-DOHC engines

  1. Position a new gasket on the cylinder head, then install the intake manifold on the head. Tighten the fasteners to 21 ft. lbs. (28 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 17: Make sure to follow the proper sequence when tightening the intake manifold-to-cylinder head retainers

  1. Remove the covering from the fuel injector holes and make sure the holes are clean. Install the fuel rail assembly to the intake manifold and tighten the screws to 17 ft. lbs. (23 Nm).
  2.  
  3. Connect the PCV and brake booster vacuum hoses.
  4.  
  5. Inspect the fuel line quick-connect fittings for damage and replace if necessary. Apply a small amount of clean engine oil to the fuel inlet tube. Connect the fuel supply hose to the fuel rail assembly. Check to be sure the connection is fastened securely by pulling on the connector.
  6.  
  7. Connect the heater tube and hose to the intake manifold.
  8.  
  9. Attach the upper radiator hose and coolant recovery reservoir hose.
  10.  
  11. Attach the coolant temperature sensor wiring.
  12.  
  13. Install the throttle body. Tighten the fastener to 16 ft. lbs. (22 Nm).
  14.  
  15. Attach the MAP and IAT