Chrysler 4591862AE Plenum-Intake Manifold

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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.

Label and disconnect the vacuum hoses and electrical connectors attached to the upper intake manifold and throttle body, including the electronic throttle control system.

Remove the fuel rails 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.

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.

To install the upper intake manifold, align it with the lower intake manifold and tighten the bolts according to the specified torque.

Disconnect the cable from the negative terminal of the battery.

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).

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