Chrysler 300/300 Touring/300C, Dodge Magnum. Manual — part 1509
MANIFOLD-INTAKE
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 suspected leak has been found.
4. Repair as required.
STANDARD PROCEDURE - INTAKE MANIFOLD VACUUM PORT REPAIR
The composite intake manifold vacuum ports can be repaired. Although, if the manifold plenum chamber is dam-
aged or cracked, the manifold must be replaced.
To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following pro-
cedure:
PARTS REQUIRED
TOOLS REQUIRED
Brass Nipple – 3/8
9
O.D. x 1/4
9
pipe thread (Speed
Control Port)
Pipe Tap – 1/4
9
- 18 NPT
Brass Nipple – 1/2
9
O.D. x 1/4
9
pipe thread (Brake
Booster Port)
Drill Bit – 7/16
9
File/Sand Paper
NOTE: While performing this procedure, avoid getting the manifold material residue into the plenum cham-
ber.
1. File or sand the remaining port back until a flat sur-
face is obtained (plane normal to nipple (port)
axis).
2. Drill out the nipple port (2) base using a 7/16” drill
bit.
3. Using a 1/4”–18 NPT pipe tap (1), cut internal
threads. Use caution to start tap in a axis same as
original nipple.
4. Apply Mopar
T
Thread Sealant to threads of repair
nipple(s).
5. Install repair nipple(s). Do not over torque repair
nipple(s).
9 - 2060
ENGINE - 2.7L DOHC - SERVICE INFORMATION
LX
REMOVAL
INTAKE MANIFOLD UPPER
1. Disconnect negative battery (1) cable.
2. Remove throttle body air inlet hose and air cleaner
housing assembly (3) (Refer to 9 - ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING
-
REMOVAL).
3. Disconnect electrical connectors from the following
components:
•
Manifold Absolute Pressure (MAP) Sensor
•
Electronic Throttle Control
•
Manifold Tuning Valve
4. Disconnect Vapor Purge hose, Brake Booster hose,
Positive Crankcase Ventilation (PCV) hose.
LX
ENGINE - 2.7L DOHC - SERVICE INFORMATION
9 - 2061
5. Remove manifold support brackets (1).
6. Remove manifold attaching bolts.
7. Remove upper manifold (2).
8. Remove foam insulator (3).
9. Inspect manifold (2) (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSPECTION).
9 - 2062
ENGINE - 2.7L DOHC - SERVICE INFORMATION
LX
REMOVAL - INTAKE MANIFOLD LOWER
1. Release fuel system pressure (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - STANDARD PROCE-
DURE).
2. Disconnect negative battery (1) cable located in
trunk.
3. Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
4. Disconnect injector electrical connectors (2).
5. Disconnect fuel supply hose (1) from fuel rail
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - STANDARD PROCEDURE).
LX
ENGINE - 2.7L DOHC - SERVICE INFORMATION
9 - 2063
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