Chrysler RG Voyager. Manual — part 960
torque curve while increasing higher rpm horse-
power.
If, for some reason, the molded-in vacuum ports
break, the composite manifold can be salvaged. The
vacuum ports are designed to break at the shoulder,
if overloaded. Additional material in the shoulder
area provides sufficient stock to repair. For more
information and procedure, (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - STANDARD
PROCEDURE). Also, if the special screws that attach
the MAP sensor, power steering reservoir, throttle
cable bracket, and the EGR tube become stripped, an
oversized screw is available to repair the stripped-out
condition. For more information and procedure,
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - STANDARD PROCEDURE)
DIAGNOSIS AND TESTING
INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM’S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR
The
composite
upper
intake
manifold
thread
bosses, if stripped out, can be repaired by utilizing a
repair screw available through Mopar
t parts. Repair
screws are available for the following manifold
attached components:
• MAP sensor
• Power steering reservoir
• EGR tube
• Throttle cable bracket
The repair screws require a unique tightening
torque specification from the original screw. Refer to
the following chart for specification.
DESCRIPTION
TORQUE*
STRIP-OUT REPAIR SCREWS ONLY
MAP Sensor Repair
Screw
4 N·m (35 in. lbs.)
Power Steering Reservoir
Repair Screw
9 N·m (80 in. lbs.)
EGR Tube Attaching
Repair Screw
9 N·m (80 in. lbs.)
Throttle Cable Bracket
Repair Screw
9 N·m (80 in. lbs.)
*Install Slowly Using Hand Tools Only
STANDARD PROCEDURE - INTAKE MANIFOLD
VACUUM PORT REPAIR
The composite intake manifold vacuum ports can
be repaired. Although, if the manifold plenum cham-
ber is damaged or cracked, the manifold must be
replaced.
To repair a broken or damaged vacuum nipple
(port) on the composite intake manifold, perform the
following procedure:
PARTS REQUIRED
TOOLS REQUIRED
· Brass Nipple – 1/4
9
O.D. x 1/8
9
pipe thread
(LDP/Speed Control Port)
· Pipe Tap – 1/8
9
- 18
NPT
· Drill Bit – 11/32
9
· File/Sandpaper
· Brass Nipple – 1/2
9
O.D. x 1/4
9
pipe thread
(Brake Booster Port)
· Pipe Tap – 1/4
9
- 18
NPT
· Drill Bit – 7/16
9
· File/Sandpaper
NOTE: While performing this procedure, avoid get-
ting the manifold material residue into the plenum
chamber.
(1) File or sand the remaining port back until a
flat surface is obtained (plane normal to nipple (port)
axis).
(2) Drill out the nipple (port) base using a 7/16”
(brake booster port) or 11/32” (LDP/speed control port
) drill bit (Fig. 116).
(3) Using a 1/4”–18 NPT (brake booster port) or
1/8”–18 NPT (LDP/speed control port ) pipe tap, cut
internal threads (Fig. 116). Use caution to start tap
in a axis same as original nipple.
RS
ENGINE 3.3/3.8L
9 - 149
INTAKE MANIFOLD (Continued)
(4) Apply Mopar
t Thread Sealant to threads of
repair nipple(s).
(5) Install repair nipple(s). Do not over torque
repair nipple(s).
REMOVAL - UPPER INTAKE MANIFOLD
(1) Disconnect battery negative cable.
(2) Disconnect inlet air temperature (IAT) sensor
electrical connector.
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Disconnect throttle and speed control cables
from throttle body (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/THROTTLE CONTROL CABLE -
REMOVAL).
(5) Disconnect make-up air hose support clip from
throttle cable bracket.
(6) Disconnect the automatic idle speed (AIS)
motor and throttle position sensor (TPS) wiring con-
nectors from throttle body.
(7) Disconnect
the
manifold
absolute
pressure
(MAP) sensor electrical connector.
(8) Disconnect the vapor purge vacuum hose from
throttle body.
(9) Disconnect the PCV hose (Fig. 117).
(10) Remove the power steering reservoir attach-
ing bolts and only loosen the nut (Fig. 118). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside. Do not disconnect hose.
(11) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
119).
(12) Remove intake manifold bolts and remove the
manifold (Fig. 120).
(13) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
Fig. 116 Intake Manifold Port Repair
1 - BRAKE BOOSTER PORT = 1/4
9
–18 NPT PIPE TAP
1 - LDP/SPEED CONTROL PORT = 1/8
9
–18 NPT PIPE TAP
2 - DRILL BIT = 7/16
9
BRAKE BOOSTER PORT
2 - DRILL BIT = 11/32
9
LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
Fig. 117 PCV HOSE
1 - HOSE
2 - PCV VALVE
Fig. 118 POWER STEERING FLUID RESERVOIR
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
9 - 150
ENGINE 3.3/3.8L
RS
INTAKE MANIFOLD - UPPER (Continued)
(14) Clean and inspect the upper intake manifold
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) and (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION).
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check manifold for:
• Damage and cracks.
• Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - UPPER INTAKE MANIFOLD
(1) If the following components were removed from
manifold, install and tighten to specifications:
CAUTION: The special screws used for the compos-
ite manifold attached components must be installed
slowly using hand tools only. This requirement is to
prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize
repair screw is available. For more information and
procedure (Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - STANDARD PROCEDURE - MAN-
IFOLD STRIPPED THREAD REPAIR).
• MAP sensor - 1.7 N·m (15 in. lbs.)
• Throttle cable bracket - 5.6 N·m (50 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Inspect manifold gasket condition. Gaskets can
be re-used, if not damaged. To replace, remove gasket
from upper manifold (Fig. 120). Position new gasket
in seal channel and press lightly in-place. Repeat
procedure for each gasket position.
(4) Position upper manifold on lower manifold (Fig.
120). Apply Mopar
t Lock & Seal Adhesive (Medium
Strength Threadlocker) to each upper intake mani-
fold bolt. Install and tighten bolts to 12 N·m (105 in.
lbs.) following torque sequence in (Fig. 121).
(5) Connect the MAP sensor electrical connector.
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 119).
Fig. 119 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
Fig. 120 INTAKE MANIFOLD - UPPER
1 - BOLT
2 - MAP SENSOR
3 - SCREW
4 - MANIFOLD - UPPER
5 - WIRE HARNESS
6 - GASKET (3 PER CYL. BANK)
RS
ENGINE 3.3/3.8L
9 - 151
INTAKE MANIFOLD - UPPER (Continued)
CAUTION: The special screws used for attaching
the EGR tube and power steering reservoir to the
manifold must be installed slowly using hand tools
only. This requirement is to prevent the melting of
material that causes stripped threads. If threads
become stripped, an oversize repair screw is avail-
able. For more information and procedure (Refer to
9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STAN-
DARD
PROCEDURE
-
MANIFOLD
STRIPPED
THREAD REPAIR).
(7) Install the power steering reservoir (Fig. 118).
Tighten screws to manifold to 5.6 N·m (50 in. lbs.).
(8) Connect throttle and speed control cables to
throttle body (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/THROTTLE
CONTROL
CABLE
-
INSTALLATION)
(9) Attach make up air hose clip into the hole in
the throttle cable bracket.
(10) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor.
NOTE: PCV valve MUST be seated into the right cyl-
inder head cover. The PCV valve hose MUST cover
the right cylinder head cover, PCV housing com-
pletely. Failure to do so may cause higher idle and
emission faults.
(11) Install PCV hose (Fig. 122).
(12) Install air cleaner and air inlet hose assembly.
(13) Connect the inlet air temperature (IAT) sen-
sor electrical connector.
(14) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD
(1) Perform fuel system pressure release procedure
(before attempting any repairs). (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
-
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 123).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 124).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 123).
Fig. 121 UPPER MANIFOLD TIGHTENING
SEQUENCE
Fig. 122 PCV HOSE
1 - HOSE
2 - PCV VALVE
9 - 152
ENGINE 3.3/3.8L
RS
INTAKE MANIFOLD - UPPER (Continued)
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