Mopar 4781035AA Intake Manifold

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Relieve the fuel system pressure and disconnect the cable from the negative terminal of the battery. For the removal of the upper intake manifold, disconnect the electrical connector from the inlet air temperature sensor, the air intake tube from the throttle body, and remove the air filter housing. Disconnect the electrical connectors from the throttle position sensor and the MAP sensor, as well as the vacuum lines for the purge solenoid and PCV valve from the intake manifold. Label and disconnect the vacuum lines for the power brake booster, Leak Detection Pump, EGR transducer, and cruise control vacuum reservoir from the fittings on the intake manifold. Disconnect the accelerator cable and cruise control cable from the throttle lever and bracket, then disconnect the EGR pipe from the EGR valve. Remove the upper manifold support bracket bolts, the dipstick from the tube, and the upper intake manifold bolts, lifting the upper intake manifold from the lower intake manifold. For the lower intake manifold, disconnect the fuel lines at the fuel rail, drain the cooling system, and remove the heater supply and radiator upper hoses at the intake manifold. Disconnect the coolant temperature sensor and the fuel injector wire harness connector, then remove the lower intake manifold support bracket upper bolts and the fuel injector electrical harness connector. Remove the power steering reservoir bolts and set the reservoir aside without disconnecting the fluid line, then remove the lower intake manifold support bracket bolts and manifold bolts, taking care not to damage the gasket sealing surfaces. Carefully scrape all traces of gasket material from both the cylinder head and the intake manifold surfaces, ensuring not to nick or gouge the aluminum. Use a straightedge and feeler gauge to check the intake manifold mating surface for warpage; if any surface exceeds the limits, replacement or resurfacing is necessary. For installation, use a new gasket for the lower intake manifold, tightening the bolts in the recommended sequence to the specified torque. Install the lower intake manifold support bracket and tighten the bolts, then reverse the removal process for the remaining components. For the upper intake manifold, apply a 1/16-inch diameter bead of RTV sealant around the intake openings of the lower intake manifold for specific models, or install a new gasket for others, then install the upper intake manifold and tighten the bolts in the recommended sequence to the specified torque. Finally, refill the cooling system, run the engine, and check for leaks.

Remove the lower intake manifold gasket retaining screws and the gasket.

Remove the power steering reservoir bolts and set the reservoir aside without disconnecting the fluid line.

Apply RTV sealant to the junctions, install the lower intake gasket, and tighten the retainer screws.

Position the intake manifold on the head, raise the vehicle and support it securely on jack stands, then install the intake manifold bolts finger tight, tightening them in a crisscross pattern starting at the center.

Ensure the mating surfaces of the cylinder heads and manifold are clean, using gasket removal solvents if necessary. Use a gasket scraper to eliminate any old sealant and clean the surfaces with lacquer thinner or acetone, removing any debris from the intake ports.

Label and disconnect any remaining vacuum lines and wires from the manifold.