Chrysler 68048131AA Intake Manifold Kit

Label and disconnect the vacuum hoses and electrical connectors attached to the upper intake manifold and throttle body, including the electronic throttle control system.

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. Refill the cooling system, run the engine, and check for leaks.

Run the engine to check for any fuel, vacuum, and coolant leaks.

Carefully use a scraper to remove any traces of old gasket material and sealant from the manifold and cylinder heads, then clean the mating surfaces.

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

Ensure the mating surfaces of the cylinder heads and intake manifold are perfectly clean, avoiding harsh chemicals on the plastic manifold. Check the O-rings on the intake manifold for damage; if they are fine, they can be reused, otherwise, install new ones ensuring they seat properly.

Install the bolts hand tight before tightening them to the specified torque in the correct sequence.

Remove the air filter housing and the intake air duct, followed by the ignition coils.