Chrysler 68048131AB Intake Manifold Kit

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Disconnect the negative battery terminals, disconnect wiring from the EGR temperature sensor and EGR valve actuator, remove the oil dipstick tube fasteners, intercooler outlet tube, air transfer tube, and air inlet, disconnect the fuel supply tubes and lines, disconnect the wiring from the sensor at the rear of the fuel rail, remove the high pressure fuel line from the dump valve, remove the fuel rail, disconnect the remaining wiring harnesses, and then the intake manifold can be removed.

After removing the lower intake manifold, clean and inspect the sealing surfaces and gaskets, replacing them if needed.

To remove the lower intake manifold, drain the cooling system and remove the upper intake manifold. Label and detach any remaining hoses and remove the fuel rail and injectors. Remove the heater hoses and coolant hoses. Loosen the remaining manifold mounting bolts/nuts and carefully break the gasket seal. Turn the manifold over, replace the O-ring on the heater supply tube, and remove all traces of old gasket material and sealant. Clean the mating surfaces with lacquer thinner or acetone. Apply RTV sealant around the front and rear cylinder head water passages and lay the new gaskets in place. Position the manifold on the engine, aligning the gaskets and manifold with the ports in the cylinder heads. Install the fuel rail and injectors, then tighten the nuts/bolts following the recommended sequence. Refill the cooling system, run the engine, and check for leaks.

Remove the ignition coils and, on 2005 models, the spark plug wires.

Clean and inspect the sealing surfaces of the upper intake manifold to the lower intake manifold, checking the gaskets for any tears or cracks and replacing them if necessary, although undamaged gaskets can be reused.

For the lower intake manifold, first remove the upper intake manifold and any interfering hoses. Remove the fuel rail and injectors.

To remove the upper intake manifold, start by relieving the fuel system pressure and disconnecting the battery cable. Then, remove the air filter housing and label and disconnect the hoses and electrical connectors attached to the intake manifold and throttle body. Remove the bolts securing the EGR pipe and the brackets from the throttle body and upper intake manifold. Loosen the upper intake manifold bolts and lift the manifold from the engine. Clean the mounting surfaces and inspect the O-ring gasket. If it's in good condition, it can be reused. Install the gasket into the groove in the upper intake manifold and then install the manifold onto the lower intake manifold, tightening the bolts in a circular pattern.

Remove the air filter housing and the intake air duct, followed by the ignition coils and, for 2005 models, the spark plug wires.

Next, remove the air filter housing, label and disconnect the hoses and electrical connectors attached to the intake manifold and throttle body, and remove the bolts securing the EGR pipe to the upper intake manifold.

Reinstall the remaining components in reverse order of removal, start the engine, and check for leaks and proper operation.

Check the O-rings on the intake manifold for damage or hardening. If they're OK, they can be re-used. If necessary, install new O-rings (Replace the intake manifold O-rings with new ones. Make sure they seat properly in their grooves).

When installing the lower intake manifold, you should ensure that the mating surfaces are clean and install new intake manifold seals. Lower the manifold into place and tighten the mounting bolts.

The next step is to disconnect the alternator and air conditioning compressor, and unbolt the ground straps.

Tighten the intake manifold cover bolts to the torque.

Next, remove the ignition coils and fuel rails, and drain some coolant. On VB engines, remove the coolant temperature sensor.

Remove the throttle body bracket if installed. Then, loosen the intake manifold mounting bolts in 1/4-turn increments until they can be removed by hand. Work in the same pattern as the tightening sequence.

The initial steps to remove the intake manifold are relieving the fuel system pressure and disconnecting the negative battery cable.

Remove the intake manifold by sliding it forward, then disconnect the MAP sensor and any other connectors. As the manifold is lifted from the engine, check for and disconnect anything still attached. Note that the mating surfaces of the cylinder heads and intake manifold must be perfectly clean when the manifold is installed.

Use a new gasket.

Disconnect the negative battery terminals, disconnect the left intercooler tube from the EGR air flow control valve, remove the EGR crossover tube, disconnect interfering wiring harnesses, remove the oil dipstick tube bolts and intake manifold bolts, install a new gasket during reassembly, disconnect the fuel injector wiring harness and pressure sensor wiring harness, remove the air intake heater mounting bolts, lift off the heater assembly and discard the gasket, use new upper and lower heater block gaskets during reassembly, and replace the intake air heater relay by disconnecting the negative battery terminals, labeling and disconnecting the trigger wires, removing the nuts from the cable terminals, and removing the relay mounting bracket bolts.