Mopar 4591846BA Intake Manifold

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Lift off the engine cover.Disengage the fuel system pressure. Disconnect battery negative cable.Remove the air cleaner housing and duct of intake air.Take out the ignition's 2005 model coils and spark plug wires.Separate brake booster vacuum hose, canister purge hose, and PCV hose. Pull out fuel rail and injectors.EGR pipe is removed from intake manifold. MAP sensor electrical connectors are switched off and throttle body connected to it.Loosen intake manifold bolts with 1/4 turn intervals, starting with outermost ones up to hand-removal point; repeat tightening process in reverse order. As manifold is raised from engine, one should check for anything still attached to manifold and disconnect it properly (CAUTION: mating surfaces of cylinder heads & intake manifold have to be perfectly clean when installing manifold but do not use abrasive cleaners or solvents on plastic manifolds as they can be damaged). Check for damage or hardening of O-rings on intake manifolds (If they are fine, then reuse them)-If necessary, replace them (Replace your Intake Manifold O-Rings with new ones: make sure that they seat well in their grooves)..The placement of this part should be done very carefully (CAUTION: don't upset rubber seals nor move the manifold back-and-forth after it touches cylinder heads or you will push seals away thus making a vacuum leak or oil leaks may develop).Torque down the intake manifolds bolts according to recommended sequence including bolt numbers on tightening procedure.Remaining steps for installation are just undoing what was done during removal process.Check for any vacuum leaks at intake manifold joints then start engine motor(s).

To begin with removing upper intake manifold, the fuel system pressure has to be alleviated and battery cable disconnected. And so, take off air cleaner housing; disconnect the hoses as well as electrical connecters from the intake manifold and throttle body after labeling them. Next remove all fasteners attaching EGR pipe plus the brackets on the throttle body and upper intake manifold. Afterwards, release bolts that hold down the upper intake manifold and raise it up above this engine. Clean sealing surfaces and inspect the O-ring gasket. If undamaged, it can be re-used. Consequently fit in an O-ring gasket into a grove of its upper intakes manifold then install the manifold onto lower intake manifold tightening bolts in a circular manner. In order to remove lower intake manifold, drain cooling system then proceed to remove upper intake manifold; thereafter label remaining hoses and detach them; finally get rid of fuel rail as well as injectors.Next remove heater hose connections followed by coolant hoses.Next loosen the remaining mounting bolts/nuts for manifolds carefully breaking seal provided by a gasket.Invert the manifolds & swap out O-ring on heater supply tube.Another important thing is to clean off any residual traces of old gasket material or sealer from these mating surfaces.Use lacquer thinner or acetone to clean mating surfaces.Apply RTV sealant around front & rear cylinder head water passages.Carefully place new gaskets on top of these.Position your manifolds over this engine ensuring that they are aligned with ports on these cylinder heads.Then put back fuel rail along with injectors.Tighten nuts/bolts following prescribed recommendation.Fill cooling system up.Run engine checking for leaks afterward.

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.

Loosen the lower intake manifold mounting bolts/nuts in reverse order until they can be removed by hand. Carefully break the gasket seal without prying between the manifold and the heads.

Check for and disconnect anything still attached to the manifold.

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.

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

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

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