How to Replace the Intake Manifold in a Chrysler Sebring

The 2.5L engine with a four-speed transmission and front-wheel drive was standard on most Chrysler Sebrings manufactured from 2004 through 2006. The intake manifold consists of an upper plenum chamber that absorbs the pulsations of the air pull into the cylinders. The lower manifold has fuel rail mounts and six injectors.

Instructions

Remove the Intake Manifold

1

Disconnect the negative (left shock tower) battery cable. Use the recommended procedure to relieve the pressure in the fuel system. Squeeze the retainer tabs together to disconnect the fuel supply lines from the fuel rail.

2

Locate the Manifold Absolute Pressure (MAP) sensor, the Intake Air Temperature (IAT) connections and the plenum support bracket at the rear of the MAP sensor and disconnect them. Remove the air inlet resonator bolt.

3

Loosen the air inlet hose clamp on the throttle body. Remove the air cleaner cover and the inlet hoses. Disconnect the electrical connects to the Throttle Position Sensor (TPS) and the Idle Air Control (IAC).

4

Take the throttle cable out of its bracket and remove the speed control cable. Pull the Exhaust Gas Recirculation (EGR) tube out of the manifold.

5

Remove the plenum support bracket behind the EGR rub and pull the upper intake plenum from the manifold.

6

Lift out the fuel rail after disconnecting the electrical fuel injector connectors. Pull the gaskets from the lower intake manifold and discard them.

Install the Intake Manifold

7

Make sure all the sealing surfaces are clean. Check the upper and lower gasket surfaces with a feeler gauge for flatness along a straight edge.

8

Install the new gaskets and connect the lower intake manifold. Use engine old to lubricate the fuel injector O-rings.

9

Connect the fuel injectors and properly seat them. Connect the fuel rails and tighten the bolts to 96 inch pounds. Reconnect the fuel injector electrical connectors and the fuel supply lines to the rail.

10

Set in the upper intake plenum with new gaskets. Torque the bolts to 13 foot pounds. Set the Exhaust Gas Recirculation EGR rube in place and apply 95 inch pounds of torque to the screws.

11

Reconnect the throttle cables, the Throttle Position Sensor TPS, Manifold Absolute Pressure MAP and Intake Air Temperature IAT sensors. Connect the Idle Air Control IAC motor connectors.

12

Replace the air cleaner assembly and connect the hose clamps with a torque of 25 inch pounds. Set the air inlet resonator bolt in place. Reconnect the negative battery cable.

13

Start the engine. Allow the car to idle and check for any leaks. Make the necessary adjustments and repairs.