Mopar 68038759AA Plenum-Intake Manifold

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Disconnect the cables from the negative terminals of the batteries. Disconnect the wiring from the EGR temperature sensor and valve actuator. Unbolt the oil dipstick tube. Remove the intercooler tube by loosening the clamp attaching the intercooler duct to the air intake housing. Remove the clamps from both ends of the air transfer tube. Remove the bolt from the P-clip for the air conditioning line, then remove the air transfer tube. Remove the six air intake screws, then remove the air intake. Clean debris from both ends of all of the fuel tubes. Loosen the two bolts of the bracket at the rear of the head that holds the injector tubes. Tilt the bracket for access to the rear injector tube. Place rags to absorb spilled fuel, then disconnect the rear four injector tubes and remove them. Don't bend the lines or allow fuel to run down the sides of the engine. Disconnect the wiring from the sensor at the rear of the fuel rail. Detach the fuel rail from the dump/overflow valve, then remove it. Detach the remaining interfering wiring connections. Remove the intake manifold bolts and lift off the manifold. Installation is the reverse of removal. Use a new gasket. Tighten the intake manifold cover bolts to the torque.

You should remove the upper dipstick tube mounting bolt and detach the throttle and cruise control cables if necessary.

Disconnect the brake booster vacuum hose and the PCV hose. Also, disconnect the electrical connectors at each injector, remove the fuel rail and injectors, and disconnect all connections from the throttle body.

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.

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.

The first step is to relieve the fuel pressure and disconnect the battery.

Place rags to absorb spilled fuel, then disconnect the rear four injector tubes and remove them. Don't bend the lines or allow fuel to run down the sides of the engine.

Disconnect the brake booster vacuum hose and the PCV hose. Also, disconnect the electrical connectors at each injector, remove the fuel rail and injectors, and disconnect all connections from the throttle body.

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.