Mopar 4621376 Intake Plenum Manifold Assembly

Before the intake manifold can be pulled off, the fuel system pressure has to be released and the battery negative terminal removed while considering to drain the cooling system including the cylinder block. Subsequently, the air cleaner assembly must be pulled off, its coil high tension spark plug lead must be disconnected as well as three spark plug leads related to the rear cylinder; finally the coil assembly must be unbolted. Remove the accelerator cable and the Throttle Valve cable from the throttle body and then removed the air intake plenum as well as the throttle body as a single unit. Climb up and unscrew the fuel injector then, unscrew the map sensor bracket bolts and then disconnect the PCV valve hose. loosen coolant tube flange bolts Turn the manifold retaining nuts in a 1/4 turn and then release to a free condition, beginning with the outer nuts. The manifold can be bolted to the cylinder heads which may stuck hence a gentle force is required to get off the gasket bond without damaging the cylinder head. In the case of installation, it is recommended that the mating surface of the cylinder heads and manifold be free from any debris and that solvents used for the removal of gaskets be applied at this time. Scrape the surfaces with gasket scraper and remove the old sealant and clean the surface as well as clearing the intake ports with lacquer thinner or acetone. Place the gaskets on the cylinder heads installing the beaded sealant side up, as well as if you bought a new manifold you have to transfer the coolant temperature sending unit and sensor from the old one, the threads needs to be coated with Teflon tape or thread sealant. Hinge the manifold into position to align the inlet and outlet ports and any other holes and securely fit the washers and nuts and tighten them in the correct sequence to the correct torque. Apply sealant on the coolant tube flange gasket, place it and tighten the bolts of the flange. Last of it, tighten the MAP sensor bracket bolts and put it into its position, you can now reverse the procedure used in removing the intake manifold, start the engine and check for oil or coolant leakage at the joints of the intake manifold.

To remove the intake manifold, turn off the ignition and open the fuel pump relay and then remove the negative terminal of the battery. Second, take out the air intake plenum, the fuel rail and injectors, being ready to drop a rag in case of spilling the fuel. Serpentine drivebelt should be slipped off, the cooling system should be diluted, and the alternator should be unbolted together with its bracket and detached. Remove the cylinder head to intake manifold strut and the upper radiator hose, unfetter the heater circulation tube and all other hoses connected to the intake manifold. Removing any remaining vacuum lines and wires from the manifold, then removing the coolant temperature sensor get one of the upper intake manifold bolts. Back out the intake manifold mounting bolts in a spiral pattern and if the manifold does not come loose put a little pry on a casting nub without mangling the gasket seating surfaces. If there are any other fittings and sensors, then move them to a new manifold if they are to be replaced, then remove the intake manifold gasket retaining bolts and raise the gasket from the engine. During installation, make sure that the mating surfaces of the cylinder heads block, manifold and gaskets are free from contaminants you may use gasket removal solvents if needed. Pull the old gasket away from the surfaces, then, carefully scrape all the debris that has accumulated on the mating surfaces with a scraper; if necessary, use a tap to thread the bolt holes. Spread rtv sealant around the front and rearretaingue of the engine block, insert the intake manifold gasket, and this taken the intake manifold slowly to the engine block engaging the mounting bolts/nuts loosely. Looshen the bolts/nuts in a sequential manner with three rotation around the center, then again in a three sequential rotation manner until they reach the required standard torque. Lastly, reconnect other parts in a backward manner, replace the oil and the filtering system, add antifreeze to the cooling system, then start the engine and verify if there are any leaks.