How to Replace Intake Manifold Gasket Set 01-09 Chrysler Sebring Dodge Stratus
Difficulty: Advanced · About 150 min · Chrysler Sebring
Replace the upper and lower intake manifold gaskets on a 2001–2009 Chrysler Sebring or Dodge Stratus, relieving fuel pressure before moving the rail and checking every vacuum, sensor, and intake connection for leaks after reassembly.
Tools you will need
- 13mm Socket
- Socket Extensions
- Flat Blade Screwdriver
- Torque Wrench
- 10mm Socket
- Ratchet
- Liquid Thread Locker
Parts and supplies
- Upper intake manifold gasket
- Lower intake manifold gaskets
- Fuel injector O-rings
Steps
Relieve fuel pressure
Work on a cool engine in a ventilated area. Follow the service procedure to depressurize the fuel system, disconnect the battery, and keep ignition sources away while the fuel rail is moved.
Remove the upper intake plenum
Disconnect the pressure sensor, intake duct, and related electrical connectors. Remove the upper plenum fasteners and lift the plenum clear without dropping debris into the lower intake.
Disconnect the air box and brackets
Loosen the intake clamps, unplug the required wiring, and remove the air box and throttle body brace fasteners. Move the components aside carefully, labeling any vacuum hoses or connectors.
Move the fuel rail and lower manifold
Remove the fuel rail retaining fasteners and disconnect the injectors and fuel line with the correct tool. Lift the rail evenly, protect the open ports, and remove the lower manifold fasteners and old gaskets.
Clean and fit new gaskets
Vacuum loose debris before wiping the mating surfaces with a suitable automotive cleaner. Keep dirt out of the intake ports, then place the new gaskets in their correct orientation without stretching or pinching them.
Reinstall the lower manifold and rail
Lower the manifold into place and start the fasteners by hand. Tighten them in the specified sequence and stages to vehicle torque values, then seat the fuel rail and injector seals evenly and reconnect the fuel line.
Reinstall the upper plenum and intake
Fit the upper manifold gasket and secure the plenum using the prescribed sequence and torque. Reconnect the MAP sensor, throttle body brace, intake duct, vacuum lines, and all wiring connectors.
Prime the fuel system and inspect
Reconnect the battery and prime the fuel system using the service procedure. Inspect the rail and injector connections for leaks before starting, then check for vacuum leaks and verify the engine idles normally.
Check your vehicle’s repair manual for exact specifications and fit.