Monday, April 23, 2012

2.5L Intake Manifold replacing?

The procedure to replace Intake Manifold on 2.5L engine.

Please Note that this Procedure Covers all U.S. and Canadian models of the Chrysler/Dodge Avenger, Chrysler Sebring Coupe and Dodge Stratus/ Stratus Coupe models for Year 1999 to 2005.

The Detailed procedure with helpful diagrams to replace intake manifold is as follows:--
Chrysler/ Dodge Intake manifold 2.5L Engine:---

  1. Disconnect the negative battery cable.
  2. Properly relieve the fuel system pressure.
  3. Disconnect the fuel line(s) from the fuel rail assembly. For quick-connect fittings, squeeze the fitting retainer tabs together and separate the connection.
    To prevent fuel from getting in your eyes, wrap shop towels around the connection to catch any gasoline spillage.
  4. Remove or disconnect the following:
    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.
    Use care, there are spacers under each fuel rail bolt.
    It may be necessary to remove the power steering fluid reservoir and mounting bracket to access all of the lower intake manifold fasteners.

    Throttle body air inlet hose clamp
    Air cleaner cover and inlet hose
    Vacuum connection from the power brake booster and the Positive Crankcase Ventilation (PCV) valve
    All remaining vacuum hoses and pipes, as necessary. Tag for identification, if necessary, to save time at assembly.

    Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature (IAT) sensor connectors
    Power steering pressure switch and Oxygen (O 2 S) sensor connectors, if necessary
    Plenum support bracket located to the rear of the MAP sensor
    Control wiring harness mounting fasteners located on top of the upper plenum near the valve cover
    Throttle Position (TP) and Idle Air Control (IAC) motor electrical connections
    Throttle body assembly
    Throttle cable bracket
    Exhaust Gas Recirculation (EGR) tube from the intake manifold
    EGR valve and transducer assembly
    Plenum support bracket located to the rear of the EGR tube
    7 upper intake plenum-to-lower manifold bolts, plenum and gasket
    Fuel injector electrical connectors
    4 fuel rail-to-intake manifold bolts and fuel rail

    Lower intake manifold bolts, intake manifold and discard the gaskets

To install:
Fig. Exploded view of the plenum and intake manifold-2.5L engine
  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. Check upper and lower manifold gasket surfaces for flatness using a straight-edge and feeler gauge.
  3. The surfaces must be flat within 0.006 in. (0.15mm) per 12 in. (30.5cm) of manifold length. The limit is 0.008 in. (0.20mm).
  4. Properly position the new gaskets on the heads and install the lower intake manifold. Torque the nuts as follows:
    1. Front bank: 60 inch lbs. (7 Nm).
    2. Rear bank: 14-17 ft. lbs. (20-23 Nm).
    3. Front bank: 14-17 ft. lbs. (20-23 Nm).
    4. Repeat once more.
  5. Lubricate the fuel injector O-rings with clean engine oil.
  6. Install or connect the following:
    Exert a slight tug on the fuel line away from the fuel rail to verify positive engagement.

    Fuel injectors
    Seat the injectors and torque the fuel rail bolts to 105 inch lbs. (12 Nm)
    Fuel injector electrical connectors
    Fuel line(s) to the fuel rail assembly

    Upper intake plenum with new gaskets and torque the bolts to 13 ft. lbs. (18 Nm)
    Plenum support brackets and tighten to 13 ft. lbs. (18 Nm)
    EGR valve and transducer assembly
    EGR tube and torque the screws to 95 inch lbs. (11 Nm)
    Throttle cable bracket
    Throttle body assembly
    TPS and IAC electrical connections
    Control wiring harness and tighten the mounting fasteners
    Power steering pressure switch and oxygen sensor connectors, if disconnected.
    MAP sensor and IAT sensor connectors
    Vacuum hose at the power brake booster and the PCV valve
    All remaining vacuum hoses and pipes
    Remaining engine control system electrical connectors
    Air cleaner cover and air inlet hose. Tighten the intake hose-to-throttle body hose clamp.
    Negative battery cable
  7. Start the engine, check for leaks and repair if necessary.
The intake manifold assembly is composed of an upper plenum and lower manifold. This aluminum alloy manifold has long runners to improve airflow inertia. The plenum chamber absorbs air pulsations created during the suction phase of each cylinder. The lower intake manifold is machined for 6 injectors and the fuel rail mounts.
Fig. Exploded view of the intake/exhaust manifolds and related components-2.5L engine

Click image to see an enlarged view
Fig. Intake manifold bolt torque sequence-1999 2.5L engine

Click image to see an enlarged view
Fig. Intake manifold bolt torque sequence-2000 2.5L engine

These details will help.


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