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Guide "how to change intake plenum" with pictures?

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Old 05-02-2011, 04:52 PM
jonthee jonthee is offline
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Default Guide "how to change intake plenum" with pictures?

Hi!

My Dodge Avenger 2.5 V6 1996 is getting more and more complete to the original and now it is time to finally replace the inner 3 spark plugs.

I have managed to get a hold of some Chilton manual for Chrysler Cirrus which has the same engine etc. but the pictures and description isn't that good, although it seems to be a pretty straight forward job I always like pictures =)

Someone who replaced the intake plenum lately (maybe you have som pictures "badvenge"?, saw your polished intake and it looks GREAT).

Something to think about that I may overlook?

Thanks!
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Last edited by jonthee; 04-15-2014 at 02:30 PM..
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Old 05-02-2011, 05:22 PM
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bad venge bad venge is offline
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My pics and how to got lost on the board transition , Mines tore down currently If I remember I'll snap pics as I reassemble
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Old 05-03-2011, 07:29 AM
jonthee jonthee is offline
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Thank you! Then I will wait until I get some pictures so nothing goes wrong.

While I wait I can install a transmission cooler and a new oxygen sensor I bought =)

Thanks again

Last edited by jonthee; 04-15-2014 at 02:31 PM..
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Old 05-03-2011, 03:10 PM
Jasonn Hormann Jasonn Hormann is offline
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I just did this last week to get to the back 3 plugs too and really it wasnt bad at all.. I have to go to work now but i can type you a detailed how to tonight if you want,, I had a haynes manual and there were a couple of bolts on the back you have to take out that the manual didnt even show...
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Old 05-03-2011, 03:47 PM
jonthee jonthee is offline
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Hi!

Yeah that would be great!

Any spec. tourqe for the bolts? Or can it be done "by feeling"?

Best regards!
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Old 05-03-2011, 04:18 PM
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There are 7 Bolts across the front
3 bolts across the rear mount
2 bolts on the EGR left side
2 bolts on the right side
4 bolts holding on the TB
1 hose holding the TB
1 hose to the Plenum near the TB
1 smaller hose rear of Plenum right side
1 Larger hose rear of Plenum left side

You should get a new gasket (about $20)

Torque is in the manual listed as 168 in-lbs.
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Old 05-03-2011, 05:03 PM
jonthee jonthee is offline
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Thank you!

No adjustments to the gaswire? It seems it is stuck/bolted on a mount to the plenum somehow? But maybe it is just to remove everything?

Would be really great with pictures if you have time, but it should be pretty simple..?

Is it very important to use that specific tourqe or can I go by feeling? (I have no such tool).

Also, is it best to have the car inside because of potential dirt/rain while working on it? My father has a workshop 25 miles from here, smartest thing to go there?

I have bought a whole gasket set (upper and lower plenum + EGR-valve-gasket), but I will only use the upper plenum and the one for the EGR-valve

Best regards
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Old 05-03-2011, 07:14 PM
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mark the throttle cable bolts and be sure to attach the ground back up

168 in pds is 14 ft pds I'd call it not really tight

A little dirt dust not bad but I'd not do it in the rain
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Old 05-04-2011, 12:24 PM
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Thank you!

I have printed the "list" you wrote so I can keep counting the things to loosen

I will try to take some pictures of everything while I replce the plugs.

Best regards
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Old 05-04-2011, 03:22 PM
Jasonn Hormann Jasonn Hormann is offline
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heh when i did mine i just left the throttle body on it,, I didnt take off any more than i had to... i got the 3 bolts in the back by the firewall and the egr bolts then the top ones picked it up flipped it over and laid it down out of the way while the throttle body and cable were still attached,,, im glad i did this those plugs under there were terrible, i think they were still the original ones and my car has 200, 000 miles on it... When i put the plenum back on I dont know anything about torque specs either but i got all the tops bolts in and worked from the inside out and just kept tightening them alittle at a time.. I think i got them all pretty tight, i hope i didnt over do it ... Anyways everything is fine so far... Oh yah and i had oil in my spark plugs so i took off the valve covers too and replaced the gaskets and there are gaskets that go on the tubes for the spark plugs that i replaced this is why i was getting oil in the plugs those gaskets were shot... Getting off the valve cover gaskets was a pain in the you know what... They were so hard and stuck, it took me along time breaking them off piece by piece.. Over all it wasnt a bad job...
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Old 05-04-2011, 03:22 PM
 
 
 
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