Chrysler 4781035AA Intake Manifold

As for the removal of the components, one has to discharge the fuel system and the cooling system and then reconnect the cable to the negative terminal of the battery. After that, take off the air filter housing and air intake duct and if applicable, cable and cruise control throttles, disconnect AIS motor, TPS and MAP sensor connectors. And remove the vapor purge vacuum hose and the PCV hose also. Disconnect the power steering reservoir if necessary but leave the fluid lines connected; unbolt the fluid reservoir and set aside. Remove the power brake booster and LDP or NVLD system vacuum hoses from the manifold then, remove EGR pipe and the upper intake manifold bolts to separate upper intake manifold from the lower intake manifold, cover the intake manifold runners to avoid debris getting in. For the lower intake manifold: remove the fuel line fitting, the ignition coil pack and the bracket, the heater supply hose, ECT; and take off the fuel rail and injector. Remove the upper clip of the upper hose and then disconnect the hose from the thermostat housing, and then unbolt the lower intake manifold and remove it from the engine, being cautious of the gasketing surfaces. Pull off the lower intake manifold gasket keeping screws and the gasket itself. While installing, make sure all areas in which mating surfaces will connect are without contaminants and if they are use gasket removal solvents to ease this process. Old gasket material must be scraped off with gasket scraper, clean the surfaces with lacquer thinner or acetone then clear the debris from the bolt holes. It is recommended to use RTV sealant on the junctions, to fit the lower intake gasket, and fasten the retainer screws. Very cautiously, immerse the lower part of the intake manifold into the matter and then very slowly attach the mounting bolts only loosely, and then tighten them in three steps only according to the sequence mentioned above. Ensure the condition of the rubber seals placed at the top of the intake manifold before replacing any that may be damaged, once done secure the upper intake manifold to the lower intake manifold by tightening the screws in harmony with each other. Last, reassembly of the additional components is done, the cooling system is refilled, the engine is started and the leaks and functions are checked.

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.