Chrysler 4591960AC Intake Manifold

To install the upper intake manifold, align it with the lower intake manifold and tighten the bolts according to the specified torque.

Remove the heater supply tube and replace the O-ring with a new one. Use a scraper to remove all traces of old gasket material and sealant from the manifold and cylinder heads, then clean the mating surfaces.

Disconnect the fuel injector electrical connectors and various vacuum hoses, labeling them as necessary. Also, disconnect the MAP sensor electrical connector, release the wiring harness clips, and remove the intake manifold bolts and nuts.

Carefully lower the lower intake manifold into place and install the mounting bolts finger-tight, then tighten the bolts in steps according to the torque specifications.

Check the O-rings on the intake manifold for damage or hardening. If they're OK, they can be re-used. If necessary, install new O-rings (Replace the intake manifold O-rings with new ones. Make sure they seat properly in their grooves).

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.

Disconnect the cable from the negative terminal of the battery.