Chrysler 4591863AM Plenum-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.

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.

Remove the air filter housing and the intake air duct.

Clean and inspect the sealing surfaces of the lower intake manifold to the cylinder head, checking the gaskets for any damage and replacing them if necessary, while undamaged gaskets can be reused.

Disconnect the cable from the negative terminal of the battery, ensuring that on 2015 and later models with an Intelligent Battery Sensor, the IBS connector is disconnected first.

Clean the mounting surfaces of the lower intake manifold and the upper manifold, inspecting the rubber O-ring gasket for any signs of deterioration; if it is in good condition, it can be reused.

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.

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

Starting with the outer bolts and working to the inner bolts, loosen the intake manifold bolts in 1/4-turn increments until they can be removed by hand. Follow the reverse of the tightening sequence.

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