Chrysler 4591863AL Plenum-Intake Manifold

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Relieving fuel pressure and disconnecting the battery is how one will remove the upper intake manifold. Next, remove the air intake duct and filter housing. Attach a name on each of the vacuum hoses and electrical connectors that are attached to the manifolds as well as throttle body including electronic throttle control system. Remove EGR pipe as well as upper support brackets of the intake manifold. On reverse order, loosen all bolts to manifold then remove it with foam insulator pad. Ensure all sealing surfaces and gaskets are clean before replacing them if necessary. Align it into position with lower intakes mainfold then tighten bolts according to specified torque for installation of upper intake manifold. With respect to lower intake manifold, first uninstall upper intakes mainfold together with those obstructive hoses around it. Fuel rail along with injectors is what should be removed next from there for lower intake manifold.It can also be done by simply loosening up mounting bolts/nuts in reverse sequence until they can be removed by hand.Carefully break this gasket seal without prying between both of those heads as well as manifolds.Accordingly, any time new seals are needed or their surfaces have become dirty or damaged.Correctly position lower intakes mainfold over these cylinder heads then install fuel rail and injectoers.Tighten using recommended pattern until final tightening.Finally, go ahead and finish remaining installation steps in opposite direction ensuring there are no leaks.

The remaining installation steps are the reverse of removal. Start the engine and check carefully for vacuum leaks at the intake manifold joints.

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.

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.

As a precaution, remove the fuel rails and injectors.

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

Remove the engine cover by pulling it straight up off the ballstuds.

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.

Position the lower intake manifold correctly over the cylinder heads and install the fuel rail and injectors. Tighten the bolts following the recommended sequence and torque.

The remaining installation steps are the reverse of removal. Start the engine and check carefully for vacuum leaks at the intake manifold joints.

Turn the manifold over, remove the heater supply tube, and replace the O-ring with a new one.