Chrysler New Yorker. Manual — part 251
• Secondary Runner Valve (SRV)
• Manifold Tuning Valve (MTV)
• Throttle Position Sensor (TPS)
• Idle Air Control (IAC)
• Intake Air Temperature/Manifold Absolute Pres-
sure (TMAP)
(5) Disconnect vacuum hoses from the following:
• Secondary Runner Valve (SRV) Reservoir
• Speed Control Reservoir
• Positive Crankcase Ventilation (PCV) Valve
(6) Remove right (Fig. 8) and left side (Fig. 9)
intake manifold supports.
(7) Remove support brackets at intake manifold
front corners and at MTV (Fig. 10).
(8) Loosen upper fastener attaching throttle body
to support bracket.
(9) Remove clips attaching EGR tubes to intake
manifold. Refer to Group 25, Emission Control Sys-
tem.
(10) Remove bolts attaching intake manifold and
remove manifold.
INSTALLATION
(1) Clean and inspect gasket sealing surfaces.
NOTE: Intake gaskets can be reused, provided they
are free of cuts or tears.
(2) Inspect gasket for cuts, tears, or deformation.
Replace gaskets as necessary.
(3) Install intake manifold and hand start all
attaching bolts.
(4) Tighten bolts gradually in sequence shown in
(Fig. 11) until a torque of 12 N·m (105 in. lbs.) is
obtained.
(5) Install right (Fig. 8) and left side (Fig. 9)
intake manifold supports.
Fig. 8 Intake Manifold Support—Right Side
Fig. 9 Intake Manifold Support—Left Side
Fig. 10 Intake Manifold Supports—Front
Fig. 11 Upper Intake Manifold Tightening Sequence
300M
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 7
REMOVAL AND INSTALLATION (Continued)
(6) Install manifold support brackets at front cor-
ners and at MTV (Fig. 10).
(7) Tighten fastener attaching throttle body to sup-
port bracket.
(8) Connect vacuum lines to: Secondary Runner
Valve, Speed Control Reservoir, and Positive Crank-
case Ventilation (PCV) Valve.
(9) Connect electrical connectors to: Intake Air
Temperature/Manifold Absolute Pressure (TMAP),
Idle Air Control (IAC), Throttle Position Sensor
(TPS), and Manifold Tuning Valve (MTV).
(10) Install EGR tubes to intake manifold. Refer to
Group 25, Emission Control System.
(11) Install throttle and speed control cables to
bracket and throttle arm.
(12) Install air cleaner housing and inlet tube.
(13) Connect negative cable to remote jumper ter-
minal.
INTAKE MANIFOLD—LOWER
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING SYSTEM COMPONENTS. SER-
VICE VEHICLES IN WELL VENTILATED AREAS AND
AVOID IGNITION SOURCES. NEVER SMOKE WHILE
SERVICING THE VEHICLE.
REMOVAL
(1) Perform fuel pressure release. Refer to Group
14, Fuel System for procedure.
(2) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(3) Remove upper intake manifold. Refer to proce-
dure outlined in this section.
(4) Disconnect electrical connectors to fuel injec-
tors and coolant temperature sensor.
(5) Disconnect heater hose quick connect tee from
heater tube at rear of manifold.
(6) Disconnect fuel supply hose from fuel rail.
(7) Remove
screw
attaching
fuel
rail
support
bracket to the throttle body support bracket.
(8) Remove bolts attaching fuel rail.
(9) Remove fuel rail and injectors as an assembly.
(10) Remove bolts attaching lower intake and
remove intake manifold.
INSTALLATION
(1) Clean all sealing surfaces.
NOTE: Gaskets can be reused provided they are
free of tears or cuts.
(2) Inspect gaskets for tears or cuts. Replace as
necessary.
(3) Position gasket and intake manifold on cylin-
der head surfaces.
(4) Install fuel rail with injectors.
(5) Install intake manifold bolts, and gradually
tighten in sequence shown in (Fig. 12) until a torque
of 28 N·m (250 in. lbs.) is obtained.
(6) Install
screw
attaching
fuel
rail
support
bracket to the throttle body support bracket.
(7) Connect fuel supply hose to fuel rail.
(8) Connect heater hose quick connect tee to
heater tube at rear of manifold.
(9) Connect electrical connectors to fuel injectors
and coolant temperature sensor.
(10) Install upper intake manifold. Refer to proce-
dure outlined in this section.
(11) Fill cooing system. Refer to Group 7, Cooling
System for procedure.
(12) With the DRB 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 ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
Fig. 12 Lower Intake Manifold Tightening Sequence
11 - 8
EXHAUST SYSTEM AND INTAKE MANIFOLD
300M
REMOVAL AND INSTALLATION (Continued)
EXHAUST MANIFOLDS
RIGHT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system. Refer to procedure in
this section.
(4) Loosen converter pipe support attaching bolt at
transaxle mount.
(5) Remove A/C belt. Refer to Group 7, Cooling
System for procedure.
(6) Lower vehicle.
(7) Remove air cleaner housing and air inlet tube.
(8) Loosen and remove V-Band clamp at exhaust
manifold connector.
NOTE: Do not reuse V-Band clamp.
(9) Remove A/C compressor attaching bolts and set
compressor aside.
(10) Remove engine oil dipstick tube.
(11) Remove air conditioning compressor bracket.
(12) Disconnect oxygen sensor electrical connector
and remove sensor.
(13) Remove
heat
shield
attaching
bolts
and
remove heat shield (Fig. 13).
(14) Remove exhaust manifold attaching bolts (Fig.
13).
(15) Remove exhaust manifold.
INSTALLATION
(1) Install exhaust manifold. Tighten bolts starting
at the center working outward to 23 N·m (200 in.
lbs.) (Fig. 13).
(2) Install heat shields and tighten attaching bolts
to 12 N·m (105 in. lbs.).
(3) Install oxygen sensor to manifold and connect
electrical connector.
(4) Install air conditioning compressor mounting
bracket.
(5) Install engine oil dipstick tube.
(6) Install air conditioning compressor and drive
belt. Refer to Group 7, for belt installation procedure.
(7) Install a new V-Band clamp and tighten to 11
N·m (100 in. lbs.).
(8) Raise vehicle on hoist.
(9) Install exhaust system. Refer to procedure in
this section.
(10) Install and/or tighten nut attaching converter
pipe supports to transaxle brackets to 47 N·m (35 ft.
lbs.).
(11) Lower vehicle and install air cleaner housing
and air inlet tube.
(12) Connect negative cable.
LEFT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system. Refer to procedure in
this section.
(4) Loosen converter pipe support attaching bolt at
transaxle mount.
(5) Lower vehicle.
(6) Loosen and remove V-Band clamp at exhaust
manifold connector.
NOTE: Do not reuse V-Band clamp.
(7) Remove electrical connector harness bracket.
(8) Disconnect oxygen sensor electrical connector.
Remove sensor from manifold.
(9) Remove heat shield attaching bolts. Remove
heat shield.
(10) Remove manifold attaching bolts.
(11) Remove manifold.
INSTALLATION
(1) Install exhaust manifold. Tighten bolts starting
at the center working outward to 23 N·m (200 in.
lbs.).
(2) Install heat shields and tighten bolts to 12 N·m
(105 in. lbs.).
(3) Install oxygen sensor to manifold and connect
electrical connector.
(4) Attach electrical connector bracket to brace.
(5) Install a new V-Band clamp and tighten to 11
N·m (100 In. lbs.).
(6) Raise vehicle on hoist.
Fig. 13 Exhaust Manifold—3.5L Engine
300M
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 9
REMOVAL AND INSTALLATION (Continued)
(7) Install and/or tighten nut attaching converter
pipe supports to transaxle brackets to 47 N·m (35 ft.
lbs.).
(8) Install exhaust system. Refer to procedure in
this section.
(9) Lower vehicle and connect negative cable.
CLEANING AND INSPECTION
INTAKE MANIFOLD
Check for:
• Damage and cracks of each section.
• Clogged water passages in end cross over and
clogged gas passages.
EXHAUST MANIFOLDS
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface with a straightedge and thickness gauge.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
TORQUE
Band (Torca) Clamp
Fastener . . . . . . . . . . . . . . . . . 61 N·m (45 ft. lbs.)
Exhaust Manifold to Catalytic Converter
V-Band Clamp . . . . . . . . . . . 11 N·m (100 in. lbs.)
Exhaust Manifold Mounting
Fasteners . . . . . . . . . . . . . . . 23 N·m (200 in. lbs.)
Exhaust Manifold Heat Shield Mounting
Fasteners . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Exhaust Support to Body Bracket
Fasteners . . . . . . . . . . . . . . . 25 N·m (215 in. lbs.)
Exhaust Support Bracket to Transaxle
Fasteners . . . . . . . . . . . . . . . . 47 N·m (35 ft. lbs.)
Intake Manifold—Lower 3.5L
Bolts . . . . . . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)
Intake Manifold Plenum—Upper 3.5L
Fasteners . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Intake Manifold Plenum Supports
Side Supports
Fasteners—M8 . . . . . . . . . . 28 N·m (250 in. lbs.)
Front Support
Fasteners—M6 . . . . . . . . . . 12 N·m (105 in. lbs.)
11 - 10
EXHAUST SYSTEM AND INTAKE MANIFOLD
300M
REMOVAL AND INSTALLATION (Continued)
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