Jeep 68048131AA Intake Manifold Kit

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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.

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

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

Loosen the manifold bolts in reverse order and remove the manifold along with the foam insulator pad.

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.

Apply a bead of RTV sealant around the front and rear cylinder head water passages before laying the new gaskets in place, install the intake manifold gaskets on the cylinder heads, and apply RTV sealant to the manifold side of the gaskets around the water passages.

Disconnect the electrical connectors from the IAT, MAP, TPS, and ECT sensors.

Ensure the mating surfaces of the cylinder heads and intake manifold are perfectly clean, avoiding harsh chemicals on the plastic manifold. Check the O-rings on the intake manifold for damage; if they are fine, they can be reused, otherwise, install new ones ensuring they seat properly.

Disconnect the electrical connectors from the MAP sensor and the throttle body.

Drain the cooling system and remove the heater hoses.

Remove the EGR pipe from the upper intake manifold, then take off the upper intake manifold support brackets.