Chrysler New Yorker. Manual — part 248
NOTE:
For ease of installing upper intake mani-
fold, install a bolt 2 – 3 turns to the rearmost
attaching hole of intake. This will properly position
lower manifold.
(3) Install fuel rail with injectors.
(4) Install manifold attaching bolts and tighten in
sequence shown in (Fig. 11) to 12 N·m (105 in. lbs.).
Remove bolt used for aligning manifold.
(5) Connect the fuel injector electrical connectors.
NOTE: Make sure fuel injectors are located in the
correct position, as upper intake manifold interfer-
ence could occur.
(6) Install
screw
attaching
fuel
rail
support
bracket to the throttle body support bracket.
(7) Connect fuel supply hose to fuel rail.
(8) Install upper intake manifold. Refer to proce-
dure in this section.
(9) 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.
INTAKE MANIFOLD—UPPER 3.2L
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove air cleaner housing and inlet hose (Fig.
12).
(3) Remove throttle and speed control cables from
throttle arm and bracket.
(4) Disconnect electrical connectors from the fol-
lowing sensors and actuators (Refer to Group 14,
Fuel System for component locations):
• 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 and left side intake manifold
supports.
(7) Remove support brackets at intake manifold
front corners and at MTV (Fig. 13).
(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 or tears. Replace gas-
kets as necessary.
Fig. 12 Air Cleaner Housing and Inlet Hose
Fig. 13 Intake Manifold Supports—Front
LH
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 9
REMOVAL AND INSTALLATION (Continued)
(3) Install intake manifold and hand start all
attaching bolts.
(4) Tighten bolts gradually in sequence shown in
(Fig. 14) until a torque of 12 N·m (105 in. lbs.) is
obtained.
(5) Install right and left side intake manifold sup-
ports.
(6) Install manifold support brackets at front cor-
ners and at MTV (Fig. 13).
(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 3.2L
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 07, Cool-
ing 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. 15) 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 07, 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. 14 Upper Intake Manifold Tightening Sequence
11 - 10
EXHAUST SYSTEM AND INTAKE MANIFOLD
LH
REMOVAL AND INSTALLATION (Continued)
EXHAUST MANIFOLDS—2.7L
RIGHT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Remove air intake plenum and air filter hous-
ing.
(3) Remove bolt attaching battery cable housing
tube to transmission housing.
(4) Remove bolts attaching EGR tube from exhaust
manifold and EGR valve. Discard gaskets.
(5) Disconnect electrical connector and remove
exhaust manifold mounted oxygen sensor.
(6) Loosen and remove V-Band clamp.
NOTE: Do not reuse V-Band clamp.
(7) Remove heat shield attaching screws and
remove heat shields.
(8) Remove exhaust manifold attaching bolts and
remove manifold.
INSTALLATION
(1) Install exhaust manifold and gasket. Tighten
bolts working from center outwards to 23 N·m (200
in. lbs.).
(2) Install heat shields. Tighten attaching screws
to 12 N·m (105 in. lbs.).
(3) Install a new V-Band clamp and tighten 10
N·m (100 in. lbs.).
(4) Install oxygen sensor and connect electrical
connector.
(5) Install EGR tube using new gaskets. Tighten
screws to 11 N·m (95 in. lbs.).
(6) Install bolt attaching battery cable housing
tube to transmission housing. Tighten bolt to 101
N·m (75 ft. lbs.).
(7) Install air inlet plenum and air filter housing.
(8) Connect negative battery cable.
LEFT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system.
(4) Remove left catalytic converter. Refer to proce-
dure outlined in this section.
NOTE: Do not reuse V-Band clamp.
(5) Remove bolt attaching transmission dipstick
housing and rotate housing away from engine.
(6) Lower vehicle.
Fig. 15 Lower Intake Manifold Tightening Sequence
Fig. 16 Exhaust Manifold—2.7L Engine
LH
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 11
REMOVAL AND INSTALLATION (Continued)
(7) Remove screws attaching the two electrical con-
nectors and harness to support bracket.
(8) Remove engine wiring harness support bracket
from cylinder head.
(9) Disconnect exhaust manifold mounted oxygen
sensor connector and remove sensor from manifold.
(10) Remove engine oil dipstick tube.
(11) Remove heat shield attaching screws and
remove heat shields.
(12) Remove exhaust manifold attaching bolts and
remove manifold.
INSTALLATION
(1) Install exhaust manifold and gasket. Tighten
bolts starting at the center working outward to 23
N·m (200 in. lbs.).
(2) Install heat shields. Tighten screws to 12 N·m
(105 in. lbs.).
(3) Install oxygen sensor and connect electrical
connector.
(4) Raise vehicle on hoist.
(5) Install bolt attaching transmission dipstick
tube.
(6) Replace the O-ring on engine oil dipstick tube
and install tube.
(7) Install catalytic converter. Refer to procedures
outlined in this section.
(8) Install a new V-Band clamp and tighten to 10
N·m (100 in. lbs.).
(9) Install engine wiring harness support bracket
to cylinder head and attach connectors to bracket.
(10) Install exhaust system. Refer to procedure
outlined in this section.
(11) Connect negative cable.
EXHAUST MANIFOLDS—3.2L
RIGHT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system. Refer to procedure
outlined in this section.
(4) Loosen converter pipe support attaching bolt at
transaxle mount.
(5) Loosen A/C belt. Refer to Group 07, 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 housing.
(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.
(14) Remove exhaust manifold attaching bolts.
(15) Remove exhaust 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 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 housing.
(6) Install air conditioning compressor and drive
belt. Refer to Group 07, for belt installation proce-
dure.
(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 out-
lined 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.
Fig. 17 Exhaust Manifold—3.2L Engine
11 - 12
EXHAUST SYSTEM AND INTAKE MANIFOLD
LH
REMOVAL AND INSTALLATION (Continued)
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