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Home >> Chrysler >> 2009 >> 300 Signature Series >> Repair and Diagnosis >> External Pages >> Different car >> Section 208 (2.4L Engine (Service Information)) >> Manifolds >> Manifold-Intake >> Installation >> Intake Manifold - Lower

Intake Manifold - Lower

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Turbo charged engines could be equipped with either an aluminum or a plastic manifold.
Fig 1: Lower Intake Manifold Seals - Naturally Aspirated Engine
GC0021603Courtesy of CHRYSLER LLC
  1. Clean all gasket surfaces.
  2. Naturally Aspirated Engine:   Position new seals on lower intake manifold.
  3. Turbocharged Engine:   Replace lower intake manifold gasket.
    Fig 2: Lower Intake Manifold Tightening Sequence
    GC0021269Courtesy of CHRYSLER LLC
  4. Naturally Aspirated Engine:   Install lower intake manifold. Tighten fasteners to 12 N.m (105 in. lbs.) in sequence shown in Fig 2.
  5. Turbocharged Engine:   Install lower intake manifold. If equipped with an aluminum manifold, tighten fasteners to 28 N.m (250 in. lbs.) in sequence shown. If equipped with a plastic manifold, tighten fasteners to 12 N.m (105 in. lbs.) in sequence shown.
    Fig 3: Identifying Lower Intake Manifold Support Bracket - 2.4L Turbo
    GC0042878Courtesy of CHRYSLER LLC
  6. Turbocharger Equipped Engine:   Install fasteners for lower intake manifold support bracket (3). If equipped with an aluminum manifold, torque fasteners to 54 N.m (40 ft. lbs.). If equipped with a plastic manifold, torque manifold fasteners to 6 N.m (55 in. lbs.).
    Fig 4: Identifying Fuel Line Connection - 2.4L Turbo
    GC0042880Courtesy of CHRYSLER LLC
  7. If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 N.m (200 in. lbs.).
  8. Connect fuel injector wiring harness.
  9. Inspect quick connect fittings for damage, replace if necessary. Refer to STANDARD PROCEDURE . Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
    Fig 5: Identifying Dipstick Tube
    GC0042877Courtesy of CHRYSLER LLC
  10. Install the screw attaching the oil dipstick tube to lower intake manifold.
    Fig 6: Identifying Thermostat & Coolant Outlet Connector
    GC0042881Courtesy of CHRYSLER LLC
  11. Install thermostat (3) and coolant outlet connector (2). Refer to COOLING .
    Fig 7: Identifying Radiator Hose
    GC0042879Courtesy of CHRYSLER LLC
  12. Install radiator upper hose (1).
  13. Install upper intake manifold. Refer to INSTALLATION .
    Fig 8: Removing/Installing Battery
    GC0042882Courtesy of CHRYSLER LLC
  14. Connect negative cable to battery (1).
  15. Fill the cooling system. Refer to COOLING .
  16. With the DRBIII® scan tool use ASD Fuel System Test to pressurize system to check for leaks.
    CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position. or Stop All Test is selected.
  17. Start engine and check for leaks.
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