Chrysler Intake Manifold Removal?

The procedure to replace Intake manifold.
Chrysler Pacifica intake manifold replacing details.

The details for
3.5L & 4.0L Engines in section 1


AND 3.8L Engine in Section 2

Section 1 is as follows:----

3.5L & 4.0L Engines

Lower manifold replacing procedure

1. Remove or disconnect the following: 
   
   NOTE

   Clean all gasket mating surfaces and inspect for distortion with a good straightedge.
   
   
   
   
   Upper radiator hose from the thermostat housing
   

   Upper intake manifold
   

   Power steering reservoir and position aside
   

   Fuel injector and Coolant temperature (CTS) sensor electrical connections
   

   Exhaust crossover bolt
   

   Heater hose from the intake manifold
   

   Coolant container hose at the thermostat housing
   

   Fuel supply hose from the rail
   

   Fuel rail bolts and rail with the injectors as an assembly
   

   Lower intake manifold bolts and manifold
   
   
   
   
   
   
   Fig. Lower intake manifold and gasket-3.5L and 4.0L engines
   
   
   
   
   Fig. Lower intake manifold tightening sequence-3.5L and 4.0L engines

To install:

NOTE

Verify that all intake manifold and cylinder head sealing surfaces are clean.

NOTE

Be sure that the extruded holes in the gasket are installed in the recessed holes in the cylinder head

1. Install or connect the following:
   
   
   Intake manifold gasket, then the lower manifold. Torque the bolts in the proper sequence to specification
   

   Fuel rail bolts and rail with the injectors as an assembly
   

   Fuel supply hose to the rail
   

   Heater hose to the intake manifold
   

   Coolant container hose to the thermostat housing
   

   Exhaust crossover bolt
   

   Fuel injector and CTS sensor electrical connections
   

   Power steering reservoir
   

   Upper intake manifold
   

   Upper radiator hose from the thermostat housing
   
2. Fill the cooling system and check for leaks.

Upper

1. Before servicing the vehicle, refer to the Precautions section.
2. Properly relieve the fuel system pressure.
3. Drain the cooling system.
4. Remove or disconnect the following:
   
   
   Negative battery cable
   

   Air cleaner assembly
   

   Engine cover from the top of the intake manifold
   

   ECT harness connector, as required
   

   Accelerator and the speed control cable from the throttle lever
   

   Two cable bracket bolts and position the bracket aside
   

   Oil dipstick tube-to-upper intake bolt
   
5. Disconnect the following electrical connections:
   
   
   Manifold Tuning Valve (MTV)
   

   Sort Runner (SR) valve
   

   Exhaust Gas Recirculation (EGR) valve
   

   Throttle Position (TP) sensor
   

   Idle Air Control (IAC) motor
   

   Intake Air Temperature (IAT) sensor
   

   Manifold Absolute Pressure (MAP) sensor
   
6. Remove or disconnect the following:
   
   
   Alternator support bracket
   

   EGR tube
   
7. Disconnect the following vacuum lines:
   
   
   Positive Crankcase Ventilation (PCV) valve
   

   Evaporative Emissions (EVAP) solenoid
   

   Brake booster
   

   Front and rear manifold support brackets
   

   Intake plenum mounting bolts
   
8. Remove the intake manifold plenum from the intake manifold.
   
   NOTE

   Discard the old gasket. Cover the intake manifold openings with tape to keep debris from entering the engine.
   
   
   
   
   

   

   Fig. Upper intake manifold and related components-3.5L and 4.0L engines
   
   
   
   

   

   Fig. Upper intake manifold support bracket-left shown, right similar-3.5L and 4.0L engines

To install:

1. Install or connect the following:
   
   NOTE

   Do not overtighten bolts when working with light alloys.
   
   
   
   
   Intake manifold plenum with a new gasket in place. Torque the mounting bolts, working from the center outward, to 105 inch lbs. (12 Nm)
   
   
   
   
   
   Oil dipstick tube-to-upper intake bolt
   

   EGR tube
   
2. Connect the following vacuum lines:
   
   
   PCV valve
   

   EVAP solenoid
   

   Brake booster
   
3. Install or connect the following:
   
   
   Alternator support bracket
   
4. Connect the following electrical connections:
   
   
   MTV valve
   

   Sort Runner (SR) valve
   

   EGR valve
   

   TP sensor
   

   IAC motor
   

   IAT sensor
   

   MAP sensor
   
5. Install or connect the following:
   
   
   Cable bracket and bolts
   

   Accelerator and the speed control cable to the throttle lever
   

   Air cleaner assembly
   

   ECT harness connector, as required
   

   Engine cover
   

   Negative battery cable
   
6. Fill and bleed the cooling system.
7. Change the engine oil and filter.
8. Start the engine, check for fuel and coolant leaks and verify correct engine operation.

------------------
Section 2 is as follows:-----

3.8L Engine

1. Drain the cooling system.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   
   CAUTION

   The intake manifold gasket is made of thin metal, handle with care to avoid injury.
   
   
   
   
   Negative battery cable
   

   Idle Air Temperature (IAT) sensor connector
   

   Air cleaner and tube
   

   Accelerator cable
   

   Cruise control cable
   

   EVAP hose from the throttle body
   

   Exhaust Gas Recirculation (EGR) tube
   

   Idle Air Control (IAC) motor and Throttle Position (TP) sensor connectors
   

   Manifold Absolute Pressure (MAP) sensor connector
   

   Positive Crankcase Ventilation (PCV) hose
   

   Brake booster and cruise control hoses
   

   Upper intake manifold bolts and manifold
   

   Fuel line
   

   Heater supply hose and Engine Coolant temperature (ECT) sensor
   

   Fuel injector harness connectors
   

   Fuel supply manifold with the injectors as an assembly
   

   Upper radiator hose
   

   Lower intake manifold bolts and manifold
   

   Intake manifold seal retainer screws and the gasket
   
4. Clean all gasket mating surfaces.

To install:

Fig. Lower intake manifold torque sequence-3.8L engine

 

Fig. Upper intake manifold torque sequence-3.8L engine

1. Install a ¹ / ₄ inch bead of gasket maker onto each of the 4 manifold-to-cylinder head gasket corners. 
   
   
   
   Fig. Install a 1/4 inch bead of gasket maker onto each of the 4 manifold-to-cylinder head gasket corners-3.8L engine
2. Install the lower intake manifold gasket and tighten the seal retainer screws to 105 inch lbs. (12 Nm)
3. Install the lower intake manifold and tighten the bolts in sequence, as follows:
   
   
   
   
   1. Step 1: 10 inch lbs. (1 Nm).
   2. Step 2: 17 ft. lbs. (22 Nm).
   3. Step 3: 17 ft. lbs. (22 Nm).
4. Install or connect the following:
   
   
   Fuel supply manifold and injectors as an assembly
   

   Fuel injector harness connectors
   

   ECT sensor connector
   

   Heater supply hose
   

   Radiator hose
   

   Fuel line
   
5. Place a new gasket in the channel and press lightly in place.
   
   NOTE

   The special screws used to retain the EGR tube must be tightened slowly with hand tools only to avoid stripping the threads.
   
   
   
   
   Upper intake manifold. Apply Mopar®thread and lock adhesive (medium strength) to each upper intake manifold bolt. Tighten the bolts to 105 inch lbs. (12 Nm) in the sequence illustrated.
   

   MAP sensor connector
   

   Brake booster and cruise control hoses
   
   
   
   
   
   EGR tube
   

   Cruise control cable
   

   Accelerator cable
   

   EVAP hose
   

   IAC and TP sensor connectors
   

   Air cleaner and tube
   

   IAT connector
   

   PCV hose
   

   Negative battery cable
   
6. Fill the cooling system.
7. Start the engine, check for leaks and repair if necessary.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html