Chrysler Sebring 2005 Service Manual page 1133

9 - 64 ENGINE 2.0L DOHC
INTAKE MANIFOLD (Continued)
(4) Remove throttle body air inlet hose and air
cleaner housing assembly.
(5) Remove throttle and speed control cables from
throttle lever and bracket.
(6) Remove EGR tube (if equipped).
(7) Remove engine oil dipstick and tube from
engine block. Plug hole in block to prevent debris or
fluid from entering engine crankcase.
(8) Disconnect necessary
intake manifold.
(9) Disconnect the fuel supply line quick connect at
the fuel rail assembly.
WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(10) Remove fastener holding fuel rail bracket to
side of cylinder head.
(11) Disconnect the following electrical connectors:
• Fuel Injectors
• Knock Sensor
• ECT Sensor
• IAC
• TPS
• MAP Sensor
• A/C Pressure Sensor
• A/C Compressor Clutch
• Generator
(12) Reposition wiring harness.
(13) Remove fuel rail support bracket (Fig. 103).
(14) Remove fuel rail.
Fig. 103 Fuel Rail Support Bracket
(15) Remove coolant outlet connector (Refer to 7 -
COOLING/ENGINE/COOLANT OUTLET HOUSING
- REMOVAL).
(16) Remove intake manifold fasteners. Remove
intake manifold.
vacuum hoses from
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
(1) Inspect manifold for cracks, distortion, or
mounting surface warpage. Replace manifold if nec-
essary.
(2) Inspect manifold for gasket surface damage or
excessive swelling. Replace manifold if necessary.
INSTALLATION
(1) Install new intake manifold and gasket. Grad-
ually tighten fasteners to 28 N·m (250 in. lbs.) in
sequence shown in (Fig. 104).
(2) Install coolant outlet connector (Refer to 7 -
COOLING/ENGINE/COOLANT OUTLET HOUSING
- INSTALLATION).
(3) Install fuel rail.
(4) Install fuel rail support bracket (Fig. 103).
(5) Connect previously disconnected electrical con-
nectors.
(6) Install fastener holding fuel rail bracket to side
of cylinder head.
(7) Inspect quick connect fittings for damage,
replace if necessary. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(8) Connect vacuum hoses to intake manifold.
(9) Install engine oil dipstick and tube.
(10) Install EGR tube (if equipped).
(11) Install throttle and speed control cables to
bracket. Connect cables to the throttle lever.
(12) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(13) Connect negative battery cable.
(14) 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.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove complete exhaust system (Refer to 11 -
EXHAUST SYSTEM - REMOVAL).
(4) Remove rear engine mount and transaxle
bracket.
JR