Dodge Stratus, Avenger and Chrysler Sebring Intake manifold Replacing Procedure?

The complete details to remove/ install intake Manifold.

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 Procedure here is for 2.0L Engine INTAKE MANIFOLD Removal.

The Details are as follows:---


2.0L Engine
This engine uses a 2-piece aluminum intake manifold. A non-reusable gasket joins the 2 halves.

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

   Use care since the fuel injectors can drop out of the fuel rail as it is being removed.
   
   
   Negative battery cable

   Accelerator cable, breather hose and air intake hose

   Vacuum connection at 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.

   Fuel line(s), the throttle control cable and brackets
   
   
   
   Alternator wiring harness

   Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature (IAT) sensor connectors

   Throttle Position (TP) sensor connector and position the engine wiring harness aside

   Exhaust Gas Recirculation (EGR) pipe connection

   Intake manifold stay and engine hanger

   Fuel injector connectors

   Throttle body assembly

   Intake manifold plenum and gasket

   Fuel rail assembly
   
   
   Intake manifold and gasket 
   
   

   

   Fig. Intake manifold hose, cable and wire attachment identification-2.0L 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 straight-edge and feeler gauge. It should be 0.006 in. (0.15mm) or less. The limit is 0.008 in. (0.20mm).
2. Install or connect the following:
   
   
   New gasket and the manifold and torque the manifold in a crisscross pattern, starting from the inside and working outwards to 17 ft. lbs. (23 Nm)

   Lubricate fuel injector O-rings with clean engine oil

   Fuel rail, injector and pressure regulator assembly
3. Thoroughly clean the mating surfaces and install the intake manifold plenum with a new gasket.
   
   
   Throttle body assembly

   Intake manifold stay and engine hanger

   Fuel injector connectors

   EGR pipe connection

   Engine control electrical connectors

   Alternator wiring harness connection

   Fuel line(s)

   Throttle control cable brackets

   Vacuum hose at the power brake booster and the PCV valve

   All remaining vacuum hoses and pipes

   Accelerator cable, breather hose and air intake hose

   Negative battery cable
4. Start the engine and check for proper operation.

The intake manifold 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.

ALSO GO THROUGH THIS ADDITIONAL HELP DETAILS:---

1. Relieve the fuel system pressure using the recommended procedure.
2. Disconnect the negative battery cable from the left shock tower.
   
   NOTE

   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.
3. Remove the air inlet resonator as follows:
   
   
   Air inlet resonator-to-throttle body screw

   Air inlet resonator-to-air inlet tube clamp, loosen it

   Resonator
4. Remove or disconnect the following:
   
   NOTE

   Wrap shop towels around the fuel line openings to catch any spilling fuel.
   WARNING

   Use care when handling the fuel injectors. Do not set them on their tips. Cover the fuel injector openings after fuel rail removal.
   
   
   Fuel supply line quick-disconnect fitting from the fuel rail. Squeeze the retainer tabs together and pull the fuel tube fitting from the fuel tube nipple. The retainer will remain on the fuel tube.
   
   
   Fuel rail
   
   
   Accelerator, kickdown and speed control cables from the throttle lever and bracket

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

   Vacuum hoses from the throttle body

   Manifold Absolute Pressure (MAP) sensor, Idle Air Control (IAC) motor and Intake Air Temperature (IAT) sensor

   Vapor and brake booster hoses

   Knock sensor electrical connector

   Starter relay electrical connector

   Wiring harness from the intake manifold tab

   Transaxle-to-throttle body support bracket fasteners at the throttle body and loosen the fastener at the transaxle end

   Throttle body assembly

   Exhaust Gas Recirculation (EGR) tube

   Intake manifold-to-inlet water tube support fastener

   Intake manifold fasteners and discard them

   Intake manifold

To install:

1. Clean all sealing surfaces. Check upper and lower manifold gasket surfaces for flatness with a straightedge. Surface must be flat within 0.006 inch (0.15mm) per foot (30cm).
   
   NOTE

   Replace all seals and fasteners with new ones.
2. Install or connect the following:
   
   
   Intake manifold with new O-ring seals. Torque the fasteners, in proper sequence, to 105 inch lbs. (12 Nm)
3. Lubricate the fuel injector O-rings with engine oil.
4. Install or connect the following:
   
   
   Fuel injector/fuel rail assembly. Torque the fuel rail bolts to 17 ft. lbs. (23 Nm)

   Fuel injector electrical connectors
5. Lubricate the quick-connect fittings with engine oil.
6. Install or connect the following:
   
   NOTE

   Tighten the support bracket at the throttle body first; then, at the transaxle.
   Tighten the EGR tube-to-valve fasteners first; then, at the intake manifold.
   
   
   
   
   Fuel supply line to the fuel rail. Pull on the connector to insure it is locked into position.

   PCV and brake booster hoses

   Throttle body and torque the fasteners to 17 ft. lbs. (23 Nm)

   Transaxle-to-throttle body support bracket. Torque the fasteners to 105 inch lbs. (12 Nm)
   
   
   
   
   MAP and IAT sensor electrical connectors

   Knock sensor electrical and starter relay connectors

   Wiring harness to the intake manifold tab

   IAC and TP sensor electrical connectors

   Throttle body vacuum hoses

   Accelerator, kickdown and speed control cables, to their bracket(s) and throttle lever

   EGR tube. Torque the fasteners to 95 inch lbs. (11 Nm)
   
   
   
   
   Fresh air duct to the air filter housing

   Air inlet resonator to the throttle body

   Air inlet tube to the resonator. Torque the clamps to 20-30 inch lbs. (2-3 Nm).

   Negative battery cable

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

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