Chrysler 4792184AE Lower Engine Intake Manifold

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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.

Loosen the lower intake manifold mounting bolts/nuts in reverse order until they can be removed by hand. Carefully break the gasket seal without prying between the manifold and the heads.

Remove the air filter housing and the intake air duct.

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

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.

Relieve the fuel system pressure.

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.

Finally, complete the remaining installation steps in reverse order and check for any leaks.

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