Chrysler 4621376 Intake Plenum Manifold Assembly

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Before the intake manifold can be pulled off, the fuel system pressure has to be released and the battery negative terminal removed while considering to drain the cooling system including the cylinder block. Subsequently, the air cleaner assembly must be pulled off, its coil high tension spark plug lead must be disconnected as well as three spark plug leads related to the rear cylinder; finally the coil assembly must be unbolted. Remove the accelerator cable and the Throttle Valve cable from the throttle body and then removed the air intake plenum as well as the throttle body as a single unit. Climb up and unscrew the fuel injector then, unscrew the map sensor bracket bolts and then disconnect the PCV valve hose. loosen coolant tube flange bolts Turn the manifold retaining nuts in a 1/4 turn and then release to a free condition, beginning with the outer nuts. The manifold can be bolted to the cylinder heads which may stuck hence a gentle force is required to get off the gasket bond without damaging the cylinder head. In the case of installation, it is recommended that the mating surface of the cylinder heads and manifold be free from any debris and that solvents used for the removal of gaskets be applied at this time. Scrape the surfaces with gasket scraper and remove the old sealant and clean the surface as well as clearing the intake ports with lacquer thinner or acetone. Place the gaskets on the cylinder heads installing the beaded sealant side up, as well as if you bought a new manifold you have to transfer the coolant temperature sending unit and sensor from the old one, the threads needs to be coated with Teflon tape or thread sealant. Hinge the manifold into position to align the inlet and outlet ports and any other holes and securely fit the washers and nuts and tighten them in the correct sequence to the correct torque. Apply sealant on the coolant tube flange gasket, place it and tighten the bolts of the flange. Last of it, tighten the MAP sensor bracket bolts and put it into its position, you can now reverse the procedure used in removing the intake manifold, start the engine and check for oil or coolant leakage at the joints of the intake manifold.

If equipped, remove the power steering pump and set it aside.

The first step is to relieve the fuel system pressure and disconnect the negative battery cable.

Label and disconnect any remaining vacuum lines and wires from the manifold.

Carefully set the manifold in place, ensuring proper alignment of all openings and holes, then install the washers and nuts, tightening them in the recommended sequence to the specified torque.

Position the intake manifold on the head, raise the vehicle and support it securely on jack stands, then install the intake manifold bolts finger tight, tightening them in a crisscross pattern starting at the center.