Mopar 68048131AB Intake Manifold Kit

After removing the lower intake manifold, clean and inspect the sealing surfaces and gaskets, replacing them if needed.

Next, remove the heater hoses and coolant hoses, loosen the remaining manifold mounting bolts/nuts in 1/4-turn increments until they can be removed by hand, and be cautious not to pry between the manifold and the heads to avoid damaging the gasket sealing surfaces.

Clean and inspect the sealing surfaces of the upper intake manifold to the lower intake manifold, checking the gaskets for any tears or cracks and replacing them if necessary, although undamaged gaskets can be reused.

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.

Tighten the mounting bolts in sequence to the specified torque, then install the upper intake manifold.

Remove the EGR pipe from the intake manifold.

Remove the EGR pipe from the intake manifold.

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.

After the cowl cover, remove the cowl support brace and the windshield wiper motor support bracket.

Complete the installation by reversing the removal steps, refilling the cooling system if drained, starting the engine, and checking for leaks and proper operation.

Disconnect the negative battery terminals, disconnect the left intercooler tube from the EGR air flow control valve, remove the EGR crossover tube, disconnect interfering wiring harnesses, remove the oil dipstick tube bolts and intake manifold bolts, install a new gasket during reassembly, disconnect the fuel injector wiring harness and pressure sensor wiring harness, remove the air intake heater mounting bolts, lift off the heater assembly and discard the gasket, use new upper and lower heater block gaskets during reassembly, and replace the intake air heater relay by disconnecting the negative battery terminals, labeling and disconnecting the trigger wires, removing the nuts from the cable terminals, and removing the relay mounting bracket bolts.

Remove the throttle body bracket if installed. Then, loosen the intake manifold mounting bolts in 1/4-turn increments until they can be removed by hand. Work in the same pattern as the tightening sequence.