Chrysler 5184199AF Intake Manifold

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Before replacing the upper intake manifold, turn off the fuel pump and remove the negative terminal from the remote ground system. Release and label the vacuum hoses and connectors at the upper intake manifold and throttle body and ETC wiring harness, then remove the air intake duct and air filter housing. Then, further remove the EGR pipe and the upper intake manifold support brackets and then loosen the manifold bolts in the reverse sequence that you tightened them; consequently, you can then take off the manifold and the foam insulator pad. The sealing surfaces and gaskets should be clean and inspected with a view of replacing the bad ones while retaining the serviceable ones. Place and secure the upper intake manifold to the lower intake manifold with the help of bolts, and turn them in the correct order. With regard to the lower intake manifold, at least initially, remove the upper intake manifold; label and disconnect any other hoses that may be in the way. Disconnect fuel rail and injectors, unbolt lower intake manifold as far as possible and then come off in turn, do not use forceful pressure between the manifold and the heads to check the gasket sealing surfaces. Ensure that the sealing surfaces' and gasket condition is okay and replace those that are badly affected. Place the lower intake manifold over the engine and make sure there are proper mating surfaces with the gaskets, install the fuel rail and the injectors. For clearance, leave the fuel rail retaining bolts to be half tightened to facilitate alignment, while tighten all the remaining lower intake manifold bolts in several passes in the sequence recommended above. Lastly, engage the engine turn it on and look for any fuel, vacuum, and coolant leaks.

To perform removal of the throttle body assembly and intake manifold together with the exhaust manifolds, it is necessary first of all to release the fuel system pressure and disconnect the negative terminal of the battery and to drain the cooling system. Next, discard the air cleaner, be sure to identify all the vacuum lines and loose them from their connectors, all electrical wires, and fuel lines and the accelerator cable from the throttle lever. If so provisioned, remove the power steering pump belt, then disconnect the power brake vacuum line to the intake manifold, then unscrew the water hoses from the coolant crossover. Lift the front part of the car with jack and fix it securely on jack stands; remove the exhaust pipe from the exhaust manifold. If fitted, unbolt the power steering pump and, with it out of the way, set aside, and then unbolt the intake manifold support bracket and sever the EGR tube from the exhaust manifold. Lose the intake manifold bolts, lower the car and unbolt the throttle body and intake manifold in one assembly, thereby detaching the throttle body and gasket from the intake manifold before placing the unit on the bench. Lose the exhaust manifold nuts and take off the exhaust manifold: dispose of old gaskets and clean all gasket contact areas. Manifolds should also be cleaned with solvent and dried by compressed air, and the mating surfaces should be examined flat in relation to the straightedge, feeler gauges and the manifolds themselves should be examined for cracks and distortion and if present they should either be replaced or resurfaced. Concerning installation, it is advisable to replace either manifold; if so, transfer the studs to the new manifold. For the SOHC apply a thin layer of gasket sealant then place the new gaskets on the manifold sides, place the exhaust manifold on the cylinder head then install the nuts and begin tightening at the center in a cross wise manner. Place the intake manifold on the head, lift the car and secure it properly on jack stands, using the new intake manifold bolts put them in loosely following the crisscross technique beginning at the middle. The rest of the procedure of installation is carried out in the reverse order to the removal procedure.

Remove the intake manifold fasteners and gasket.

Remove the heater supply tube and replace the O-ring with a new one. Use a scraper to remove all traces of old gasket material and sealant from the manifold and cylinder heads, then clean the mating surfaces.

Clean all gasket surfaces before installing the new manifold with a new gasket, tightening the fasteners gradually and evenly in the specified sequence, and complete the installation in reverse order of removal.

Remove the support bracket-to-upper manifold nuts, loosen the bolts on the manifold without removing them, and then take off the upper intake manifold.

Remove the wiring harness retainers from the upper intake support bracket and the retainer from the stud bolt. Then, remove the nuts and stud bolt to take off the upper intake manifold bracket, followed by the nut from the bracket on the heater core return tube.

Loosen the remaining manifold mounting bolts/nuts in 1/4-turn increments until they can be removed by hand, and move the ignition coil capacitor out of the way.

Remove the EGR pipe from the intake manifold.

Position the lower intake manifold onto the engine, ensuring proper alignment with the gaskets, and install the fuel rail and injectors. Loosely install the fuel rail retaining bolts for alignment, then install the remaining lower intake manifold bolts and tighten them in several steps according to the recommended sequence.

Disconnect the fuel line to the fuel rail and remove the fuel injectors and fuel rail, noting that the lower intake manifold can be removed with the injectors and fuel rail in place.

To begin the process, relieve the fuel pressure and disconnect the cable from the negative terminal of the battery.

Install the gasket into the groove in the upper intake manifold, then place the upper intake manifold onto the lower intake manifold, tightening the bolts in a circular pattern starting with the center bolts.

Remove the coolant temperature sensor.

Next, remove the air cleaner assembly, disconnect the coil high tension spark plug lead along with the three spark plug leads to the rear cylinder, and then remove the coil assembly.

The remainder of installation is the reverse of removal. Start the engine and check carefully for vacuum leaks at the intake manifold joints.

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.

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

To remove the upper intake manifold, you need to disconnect various electrical connectors, hoses, and wiring harness retainers. Then, you should loosen the upper intake manifold bolts and remove it, discarding the upper-to-lower intake manifold seals. If necessary, remove the insulator from the left valve cover.

Tighten the intake manifold cover bolts to the torque.

The lower intake does not come with gaskets. The upper gaskets are part number 5184562AC. The lower are part number 5184331AC