Chrysler Neon 1997 - Intake Manifold and Exhaust System
Chrysler Neon 1997 - Intake Manifold and Exhaust System
Chrysler Neon 1997 - Intake Manifold and Exhaust System
BAND
ISOLATOR
CLAMP
EXHAUST
CONVERTER
LOCATIONS
MUFFLER
(TORCA)
PIPE
page page
HEAT SHIELDS
The heat shield (Fig. 4) is needed to protect both
the car and the environment from the high tempera-
tures developed in the vicinity of the catalytic con-
verter.
Refer to Group 23, Body and Sheet Metal for ser-
vice procedures.
DESCRIPTION AND OPERATION This long branch fan design enhances low and
midrange torque.
INTAKE MANIFOLD SOHC
The intake manifold is a molded plastic composi- EXHAUST MANIFOLD
tion, attached to the cylinder head with ten fasten- The exhaust manifold is made of nodular cast iron
ers. This long branch design enhances low and for strength and high temperatures. Exhaust gasses
midrange torque. If removing the intake manifold for exit through a machined, articulated joint connection
any reason, the fasteners can not be reused. to the exhaust pipe.
HEATED
GEN
HEAT
SHIELD
SENSOR
EXHAUST
WIRE
OXY- PIPE CATALYTIC TORCA
VERTER
CON-
SPRINGS
CLAMP
BOLTSDOWNSTREAM
OXYGEN
FLANGE
SENSOR
HEATED
INSTALLATION
Before installing manifold. Clean all mating sur- INTAKE MANIFOLDDUAL OVERHEAD CAM
faces. Replace all seals, with new seals. All intake ENGINE (DOHC)
manifold fasteners and washers are to be discarded
and NEW fasteners and washers are to be used. REMOVAL
(1) Install intake manifold onto cylinder head and
tighten fasteners to 12 Nm (105 in. lbs.) in sequence WARNING: RELEASE FUEL SYSTEM PRESSURE
shown in (Fig. 18). BEFORE SERVICING FUEL SYSTEM COMPONENTS.
(2) Install intake manifold to water inlet support SERVICE VEHICLES IN WELL VENTILATED AREAS
fastener (Fig. 18) tighten to 12 Nm (105 in. lbs.). AND AVOID IGNITION SOURCES. NEVER SMOKE
(3) Remove covering from fuel injector holes and WHILE SERVICING THE VEHICLE.
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 Nm (200 in. (1) Disconnect negative cable from battery.
lbs.). (2) Remove fuel filler cap.
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD PL
REMOVAL AND INSTALLATION (Continued)
(3) Remove fresh air inlet duct (Fig. 21). Remove
wing nut on intake.
(4) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 19).
EGR TUBE
INTAKE
FOLD FASTEN-
MANI-
ERS
TO EGR
TUBE VALVE
FASTENERS
TO
FUEL
MAP/IAT
TEST
INJECTORS
FUEL
SENSOR
PORT
RAIL
Fig. 23 Idle Air Control (IAC) Motor and Throttle Fig. 25 Knock Sensor Electrical
Position Sensor (TPS) Wiring Connectors
INSTALLATION
Before installing manifold. Clean all mating sur- Fig. 27 Intake Manifold Tightening Sequence
faces. Replace all gaskets, with new. (2) Remove covering from fuel injector holes and
(1) Install intake manifold onto cylinder head and insure the holes are clean. Install fuel rail assembly
tighten fasteners to 28 Nm (250 in. lbs.) in sequence to intake manifold. Tighten screws to 23 Nm (200 in.
shown in (Fig. 27). lbs.).
(3) Connect PCV and brake booster hoses.
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD PL
REMOVAL AND INSTALLATION (Continued)
(4) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Lube tube with clean 30w engine oil,
Connect fuel supply hose to fuel rail assembly. Check
connection by pulling on connector to insure it locked
into position.
(5) Install throttle body. Tighten fastener to 22
Nm (200 in. lbs.).
(6) Connect Manifold Absolute Pressure/Intake Air
Temperature Sensor (TMAP) wiring connector.
(7) Connect knock sensor connector and starter
wires. Connect wiring harness to intake manifold
tab.
(8) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(9) Connect vacuum hoses to throttle body.
(10) Install accelerator, kickdown and speed con- Fig. 28 Exhaust Manifold Heat Shield
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(11) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 Nm (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 Nm
(95 in. lbs.).
(12) Install clean air duct.
(13) Install fresh air duct to air filter housing.
Tighten clamp to 3 Nm (25 in. lbs.).
(14) Connect negative battery cable.
(15) With the DRB scan tool use ASD Fuel System Fig. 29 Exhaust Manifold
Test to pressurize system to check for leaks.
tighten to 23 Nm (200 in. lbs.) starting at center and
CAUTION: When using the ASD Fuel System Test, progressing outward in both directions. Repeat this
the Auto Shutdown (ASD) relay will remain ener- procedure until all fasteners are at specified torque.
gized for 7 minutes or until the ignition switch is (2) Install exhaust manifold heat shield.
turned to the OFF position, or Stop All Test is (3) Connect upstream heated oxygen sensor con-
selected. nector.
(4) Install air cleaner bracket and assembly.
(5) Attach exhaust pipe and tighten fasteners to 28
EXHAUST MANIFOLD Nm (250 in. lbs.)
REMOVAL
(1) Remove air cleaner assembly and bracket. CLEANING AND INSPECTION
(2) Remove exhaust manifold heat shield (Fig. 28).
(3) Disconnect upstream heated oxygen sensor con- INTAKE MANIFOLD SOHC
nector.
INSPECT AND CLEAN
(4) Remove exhaust pipe from manifold.
Check for:
(5) Remove 8 exhaust manifold retaining fasteners
Inspect manifold for cracks or distortions.
and remove exhaust manifold (Fig. 29).
Check for torn or missing O-rings at the mating
INSTALLATION surface of the manifold (Fig. 30).
NOTE: Discard gasket and clean all gasket sur- INTAKE MANIFOLD DOHC
faces of manifolds and cylinder head.
INSPECT AND CLEAN
(1) Set exhaust manifold and gasket in place. Check for:
Apply Loctite 271 or equivalent to fasteners and Inspect manifold for cracks or distortions.
THROTTLE
TO MANIFOLD
GASKET
BODY CAPTIVE
INJECTOR
O-RING RAIL
GASKET
MOUNTS
SPECIFICATIONS
TORQUE CHART