Mopar 4591960AB Intake Manifold

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

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.

To remove the upper intake manifold, start by relieving the fuel pressure and disconnecting the battery. Then, remove the air intake duct and filter housing.

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.

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

The mating surfaces of the cylinder heads and intake manifold must be perfectly clean when the manifold is installed, but don't use harsh chemicals or solvent on the plastic manifold, as it could become damaged.