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Lower Intake Manifold

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Battery-Removal/Installation
GC0042876Courtesy of DAIMLERCHRYSLER CORP.
1 - BATTERY
WARNING: Release fuel system pressure before servicing system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle.
NOTE: Turbo charged engines could be equipped with either an aluminum or a plastic intake manifold.
  1. Perform fuel system pressure release procedure before attempting any repairs  (Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)  . 
  2. Disconnect negative battery cable (1).
  3. Remove upper intake manifold (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD UPPER - REMOVAL)  .
    Fig 2: DRAINCOCK
    GC0042872Courtesy of DAIMLERCHRYSLER CORP.
    1 - RADIATOR
    2 - DRAINCOCK
  4. Partially drain (2) cooling system below thermostat level, (Refer to DRAINING COOLING SYSTEM - 2.0/2.4L ).
    Fig 3: RADIATOR HOSE
    GC0042873Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RADIATOR HOSE
    2 - LOWER INTAKE MANIFOLD
  5. Remove upper radiator hose (1).
    Fig 4: Thermostat and Coolant Outlet Connector
    GC0042875Courtesy of DAIMLERCHRYSLER CORP.
    1 - TIMING BELT COVER
    2 - OUTLET CONNECTOR
    3 - THERMOSTAT
    4 - THERMOSTAT HOUSING
  6. Remove coolant outlet connector (2) and thermostat (3) (Refer to COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL) .
    Fig 5: FUEL LINE CONNECTION - 2.4L TURBO
    GC0042874Courtesy of DAIMLERCHRYSLER CORP.
  7. Disconnect the fuel supply line quick connect at the fuel rail assembly (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
    WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.
  8. Disconnect fuel injector wiring harness.
    Fig 6: Dipstick Tube
    GC0021182Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIPSTICK TUBE
    2 - COOLANT TEMPERATURE SENSOR
    3 - SCREW
  9. Remove screw (3) attaching the oil dipstick tube (1) to lower intake manifold. See Fig 6.
    Fig 7: Lower Intake Manifold Support Bracket - 2.4L Turbo
    GC0021186Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER INTAKE MANIFOLD
    2 - LOWER INTAKE MANIFOLD
    3 - SUPPORT BRACKET
    4 - DIPSTICK TUBE SCREW
  10. Turbocharger Equipped Engine:   Remove fasteners for lower intake manifold support bracket (3). See Fig 7.
    Fig 8: Lower Intake Manifold Tightening Sequence
    GC0021269Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove lower intake manifold fasteners. See Fig 8.
  12. Remove lower intake manifold.
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