Mopar 68194114AC Engine Intake Manifold Kit

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To take out the intake manifold, begin by releasing fuel system pressure and disconnecting negative battery cable. Afterwards, undo all of the electrical connectors, hoses and wiring harness retainers that help in removing the upper intake manifold. Break away the upper intake manifold bolts and discard both it and its seals between the upper-to-lower intake manifolds. Get rid of insulator from left valve cover if necessary. For lower manifold removal, follow these steps for taking apart an upper manifold plus disconnect a fuel line, remove fuel injectors as well as fuel rail. By prying off the wiring harness retainer on one end of the manifold, remove lower intake manifold bolts. Discard seprate head-to-manifold seals .Ensure clean mating surfaces when installing lower intake manifold and introduce new item seals. Lower into position while tightening mounting bolts; finally install uppper inlet by checking rubber rings conditions putting insulators on mounting pins if neccessary then tighten mounting bolts.The remainder of the installation is the reverse of removal.

Begin by switching off the fuel pump and removing battery terminals. Then, remove the air cleaner duct-work assembly, detach and label vacuum hoses as well as electrical connectors leading to intake manifold. Disconnect the alternator and air conditioning compressor then unbolt ground straps. Remove dipstick tube upper mounting bolt and unhook throttle and cruise control cables in necessary cases. Remove ignition coils and fuel rails, draining some coolant first. On V8 engines eliminate the coolant temperature sensor . Remove intake manifold mounting fasteners being careful not to spoil gasket sealing surfaces. Label hoses or wires that are left behind after which raise the intake manifold out of the engine compartment . On installation, clean up all sealing surfaces , change any defective gaskets and position outlet pipe properly on top of cylinder heads. Finally, tighten bolts on intake manifold until they reach recommended torque using hands before final tightening with tools such as torque wrenches. Conclude with reinstallation process to fill up cooling system while checking for leakages related issues.

Use a new gasket.

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

Unbolt the oil dipstick tube.

To install the upper intake manifold, you should check the condition of the rubber seals. If necessary, place the insulator on the mounting pins. Then, tighten the mounting bolts. The remainder of the installation is the reverse of removal.

Disconnect the negative battery terminals, disconnect wiring from the EGR temperature sensor and EGR valve actuator, remove the oil dipstick tube fasteners, intercooler outlet tube, air transfer tube, and air inlet, disconnect the fuel supply tubes and lines, disconnect the wiring from the sensor at the rear of the fuel rail, remove the high pressure fuel line from the dump valve, remove the fuel rail, disconnect the remaining wiring harnesses, and then the intake manifold can be removed.

The next step is to disconnect the alternator and air conditioning compressor, and unbolt the ground straps.

Check the 0-rings on the intake manifold for damage or hardening. If they're OK, they can be re-used. If necessary, install new 0-rings and make sure they seat properly in their grooves.

Remove the intake manifold by sliding it forward, then disconnect the MAP sensor and any other connectors. As the manifold is lifted from the engine, check for and disconnect anything still attached. Note that the mating surfaces of the cylinder heads and intake manifold must be perfectly clean when the manifold is installed.

Remove the intake manifold bolts and lift off the manifold.

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.

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.

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

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.

The manifold does not come with the actuator but it does come with the internal flappers.