Spark Plug Guide

[tinosa]

Looking at the engine from the front of my '06 is a trapezoid plastic fabrication. The base of the trapezoid is at the front, near the check oil dip stick. The top of the trapezoid extends over the valve cover and is connected to a large diameter tube connected to metallic object, just off center on the drivers side. The trapezoid contraption is embossed with 2.4 L Turbo and a Chrysler Emblen. It seems that the trapezoid plastic fabrication partially covers spark plugs #'s 2 & 3, prohibing access to the plugs.

The question is " how does a person remove the "plastic trapozoid fabrication" to gain access to spark plugs # 2 & 3?

[gschnu]

Hi,

this "trapezoid part" (called upper half of the inlet manifold) is made of cast alloy on earlier GT's and was made of plastic later.

It has not to be removed comletely to change the saprk plugs but has to be loosened.

There are 7 screws at the broader base (near the dipstick) and 2 or 3 screws at the other end of it (near the throttle body), that have to be removed. If these screws are removed, the inlet manifold can be moved carefully. You have to take care not to scratch the surface where the gasket between upper an lower part of the manifold is installed.

Take care!

Georg

[garciaag]

question....how important is it to have that bolt in step six? i was changing my plugs and wires and discovered no bolt. brass fitting yes but no bolt. called chrystler and they couldnt tell me any info unless of course "i bring it in for them to look at" they were able to give me the dimmensions 6mm 1 by 16. of course one i got doesnt look like the one pictured!

[CREWZIN]

It's been awhile since I changed plugs and wires, but if I remember correctly, there's 3 bolts that hold the throttle body to the upper manifold and your looking at just one of them. As I said, I think I can remember using the same socket for all three bolts, so if you take of the other bolts out (you said your only missing one) you should be able to match the one you took off with a new one. First you can try using one of the other bolts in the hole that is missing a bolt to make sure it's the same size.

I do think you need it so there's no gap where the bolt is missing and cause a vacuum leak between the throttle body and manifold.

[garciaag]

yes 3 bolts the 2 to the tubing that are different lengths and the other one to the right of the engine that holds the throttle body and bracket together with the nice little brass fitting...well the one with the brass fitting is the bolt i am missing. the other 2 are fine although i did have that question about how tight those need to be placed. looking at the whole thing again when i get home.

[Hooligan]

Isn't those bolts to the EGR valve? They do not have to be torqued. Tighten them snug, not hammered.

[garciaag]

i loosened those bolts up and tried to replace the other 13mm bolt that uses the brass fitting. when i called the dealer they said 6mm 1 by 16 , but that has to be bs....does the 13mm mean i need the bolt size 13mm? i showed the guy at the bolt store the brass fitting and said it wouldnt fit into the fitting. thats what i get for asking the dealer! should have asked you guys! thanks in advance!

[66CUDA]

Great pictorial..I'm going to tackle this task this weekend!...I breezed thru the all the posts and have two questions. Is there a certain order to follow when retightening the manifold bolts and what is torque lbs. spec. for those bolts? If not I'll tighten them in a zig zag pattern to ensure proper closure.

66CUDA

[CREWZIN]

Upper intake manifold torque specs: Turbo and Non-turbo:

105 in-lbs or 12Nm

Tightening sequence. Middle, right, left, far right, far left.

[66CUDA]

Thx...I also just found an old post that had the info. I need to work on my forum search techniques...lololol.