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How to Replace Intake Manifold Gasket Set 01-09 Chrysler Sebring Dodge Stratus

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How to Replace Intake Manifold Gasket Set 01-09 Chrysler Sebring Dodge Stratus

Created on: 2013-10-29

Learn how to replace the intake manifold gasket on your 01-09 Chrysler Sebring or Dodge Stratus with this helpful video from 1A Auto.

  1. step 1 :Release the pressure from the fuel system
    • With the engine running, remove the fuel pump relay from the fuse block.
    • This will stop the engine and release the pressure in the fuel system.
  2. step 2 :Remove the upper intake manifold.
    • Use a 10 mm socket and ratchet to remove the upper intake manifold.
    • Disconnect the air pressure sensor.
    • Remove the 8 ten mm bolts.
  3. step 3 :Remove the air box
    • Loosen the clamp and the bolt securing the air box.
    • Disconnect the hose and wiring harness.
    • Remove the 13 mm bolt that goes into the throttle body and brace.
    • Pull the gasket off the top of the cowl and now you can remove your intake manifold.
  4. step 4 :Remove the lower intake manifold.
    • Pry up the gaskets.
    • Remove the four 10 mm bolts under the intake manifold to get at the fuel rails.
    • Disconnect the throttle position sensor if you need to.
    • Pull the fuel rails up and out.
    • Stuff a clean rag in the intake to keep anything from falling into it. (this would be bad)
    • Disconnect the wiring harness connectors from the injector.
    • Remove the lower intake manifold, having someone help hold the upper intake manifold out of the way.
    • Use a vacuum to remove any debris.
    • Remove the lower intake manifold gaskets.
    • Install the new gaskets.
  5. step 5 :Reassemble the intake manifold
    • Replace your lower intake manifold.
    • Push your fuel rails back into place.
    • Apply some loc-Tite to the four 10 mm bolts and snug them down with a socket and ratchet.
    • Bolt down the intake manifold.
    • Torque the 10 mm bolts to 105 inch/pounds, alternating the bolts you tighten working from the center out.
  6. step 6 :assemble everything else
    • Reconnect the air pressure sensor
    • Bolt in the 13 mm bolts securing the bracket to the throttle body, and torque to 15 foot/lbs
    • Reinstall the air box.
    • Tighten the clamp that connects the intake to the throttle body
    • Reconnect the hose and double check all of your sensors are connected.
    • Reinstall the fuel pump relay.
    • Seat the cowl gasket.

Tools needed for replacement

  • Materials, Fluids, and Supplies

    Liquid Thread Locker

  • Ratchets & Related

    Socket Extensions

    Torque Wrench

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

  • Sockets - Metric

    13mm Socket

    10mm Socket

Installation Video
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Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the internet. Hi, I'm Don from 1A Auto. I hope this how-to video helps you out. The next time you need a part for your vehicle, think of 1AAuto.com. Thanks.

In this video, we're going to show you how to replace an intake manifold gasket on this 2004 Chrysler Sebring. It has a 2.7 liter V6 and this process is pretty much the same for any vehicle that has a 2.7 liter V6 from this era. You'll need a gasket set from 1aauto.com, flat blade screwdriver, 10 and 13mm socket with a ratchet and extension, torque wrench and you need that torque wrench to measure inch pounds shop vacuum and some Loc-Tite.

Start out using a 10mm socket and ratchet or a wrench and remove the cover that's right next to the throttle intake. Under that, you'll see a 10mm bolt and then all seven of the other 10mm bolts that hold the upper intake manifold down. Disconnect your manifold pressure sensor just by pushing on a tab and pulling and then, I'm going to fast forward here as we remove those eight 10mm bolts. You just basically back them out. The only one that you pull out is the last one that was underneath that cover.

First, you're going to remove your air box, loosen that clamp. There's also usually another bolt down where his forearm is that holds the air box to the frame but you could see, remove the sensor, the hose and then pull the air box up and out. Underneath, there's a 13mm bolt that goes through a brace into the throttle body and we'll remove that. Now, pull of the gasket on top of the cowl just a little bit and you can pull your intake manifold up. You can do this now or you can do it after you take the lower intake manifold out, but just pry up under the gaskets and pop them up and out, and then we'll take the lower manifold out to get the lower ones out. An eight 10mm bolts hold the lower intake manifold in so you see, we just have a 10mm socket and ratchet and we'll remove those.

Obviously right now, you have the inside of your engine exposed so you want to be very careful not to drop anything down in. So be very careful with those bolts. You can see we just went to an air ratchets to save us a little time. As you can see, it's also helpful to have a helper just hold that upper intake up and you can see, as we get towards the back bolts, we have to disconnect the throttle position sensor in order to lift the intake up enough. Now, you want to pull the injectors up and out and you'd see we just grab firmly on to the rail, both parts of it, pull up and out and then grab firmly on the other side, pull it up and out.

Now, you can remove the lower intake manifold and you can see it's helpful to have somebody just grab that upper intake manifold and pull it up out of the way for you. Use a shop vac or any kind of vacuum and just vacuum out any debris that might be in there. As you saw before, the lower gaskets do the same thing, just pry them up and out with a small screwdriver, and then the new ones have a tab on them so they can only go in one way. Just line the tab up correctly, push them down in and we'll just fast forward as we pull the rest of those out and swap the new ones in as well as we put the new upper gaskets on. Again, have somebody help you out by holding up that upper intake and pull up the fuel injector rail and slide your lower intake manifold in, being careful not to displace any of those gaskets.

Now, you can push your fuel injectors right back down into place. I'm going to speed up it up here. We put some Loc-Tite on all these bolts and just kind of thread them in. Here, we're not even tightening down, we're just getting them close. We still want to be able to move the lower intake manifold around. We need to line up one more bolt before we tighten it. Here, for this last bolt where the long bolt from the upper goes in, you want to move it around and line it up. You could see, we put the long bolt in there to kind of hold its place. Now, this is a diagram of the tightening order, so you want to start with that first bolt that's kind of the middle, second bolt and then kind of go out from there. You want to tighten the bolts up in this order.

With that long bolt still in there, we tighten up the first one 105 inch pounds on these bolts and then we'll tighten up the second one. Pull that bolts out of there and then again, like I said, we can tighten up the rest of them to 105 inch pounds. Pull that cowl gasket all away again and lower your intake manifold down into place and push it down on once it's lined up. Just like before, we'll fast forward here as we just pull the bolts down in and start them in and you want to use kind of the same order tighten them up, you start the middle two and work your way out as you torque them and again, we'll torque this to 105 inch pounds.

Reconnect your air pressure sensor and we're going to reinstall that 13mm bolts that holds the bracket to the throttle body and tighten that up to about 15 foot pounds. Put the cover back on top and tighten down that 10mm bolt until it's firm and then we'll reinstall our air box and tighten up the clamp that holds the intake hose, the throttle body, reconnect the hose and reconnect any of the sensors you might have disconnected. Don't forget to reinstall your fuel pump relay or else your car will not start.


We hope this helps you out, brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the internet. Please feel free to call us toll-free, 888-844-3393. We're the company that serves you on the internet and in person.

Tools needed for replacement:

    Materials, Fluids, and Supplies

  • Liquid Thread Locker

  • Ratchets & Related

  • Socket Extensions
  • Torque Wrench
  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 13mm Socket
  • 10mm Socket

2005 - 2009  Chrysler  300
1998 - 2004  Chrysler  Concorde
2005 - 2008  Dodge  Magnum
2001 - 2006  Dodge  Stratus
2006 - 2009  Dodge  Charger
1998 - 2004  Dodge  Intrepid
2001 - 2009  Chrysler  Sebring
2008 - 2009  Dodge  Avenger
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