Mopar 4593915AA Intake Manifold

You need to free the fuel system pressure in 2014 and earlier models before you can take out the lower intake manifold. Also disconnect the negative battery cable from either the remote ground terminal or the battery. If equipped, remove the engine cover. You'll need to do three steps. Release the retainer holding the upper radiator hose to the upper intake manifold first. Next, loosen the resonator hose clamp, pull the attaching pin, and take away the resonator. Take off the wiring plugs from the MAP sensor and ETC, detach the PCV valve hose, vapor purging line, and brake booster hoses. Unplug the wiring retaining clips from both the upper intake support bracket and the stud bolt, and take off the supporter and bolt after removing all the nuts. Loosen the manifold bolts while removing the support bracket nuts, withdrew the brackets, and extracted the upper intake manifold. Take off the six seals connecting the upper and lower intake manifold pieces and put a cap on the open ports to stop dust and debris from reaching the engine. Take off the insulator if you need to from the front valve cover. Separate the fuel line from the rail, pull out the fuel injectors and fuel rail as a single unit from the lower intake. You can safely take out the lower intake with injectors and rail still attached, but treat the fuel injectors with care. Take off the six bolts that hold the lower intake manifold in place, detach the wiring harness retainer at the manifold's end, and slide the wiring aside. Lift off the manifold after prying away the plastic retainers that hold it to the cylinder heads. Keep the six metal seals for reuse. To put the lower intake in place, clean all connections between the cylinder heads, cylinder block, and intake before you start. Before putting new material and sealant on, use a gasket scraper to get rid of any old gasket material and sealant residue. Then clean the matching surfaces carefully with acetone or lacquer thinner. When you take out the fuel injectors and rail, also put in fresh intake manifold seals onto the manifold. Put the lower intake manifold in carefully, place the mounting bolts only by hand at first, and tighten them according to this order: 20 Nm, then 69 Nm. Replace rubber seals below each intake port on the upper intake manifold, and repair any damaged ones. Line up the insulator on the upper intake manifold pin, then press the upper onto the lower one, pulling the bolts up as you go. Install them in sequence and tighten with the recommended torque force. To finish, put fresh coolant back into the system, switch on the engine, and make sure everything works correctly and there are no fluid leaks.

First step toward the process of replacing the upper intake manifold is followed by releasing the fuel system pressure and by disconnecting the negative battery cable from the remote ground terminal. Pull off the air filter housing, and then gather all the connecting hoses and electrical connections of the intake manifold and the throttle body then detach them and label them. Third, unbolt the EGR pipe from the upper intake manifold and, then, take off the brackets mounted on the throttle body and on the right side of the upper intake manifold. Finally, turn the upper intake manifold bolts anticlockwise, starting from the outside bolts toward the inside, then take out the upper intake manifold. Remove the gasket and clean the surfaces to where the lower intake manifold will be mounted as well as the upper manifold of any debris or deposits; the rubber O-ring gasket should still be good, and you just re-use it. Put the gasket into the groove in the upper intake manifold and then put the upper onto the lower intake manifold and tighten the bolts in a star pattern from center bolts. For the lower intake manifold, you should first drain the cooling system and the upper intake manifold: make sure that the engine is cool. Remove any hoses, which are still connected but get in the way of the removal of the lower intake manifold then remove the fuel rail and injectors, also remove heater and coolant hoses. Tighten/Loosen the rest of the manifold mounting bolts/nuts in rotational order of 1/4 turn each time until you get to the torque that allows you to turn the bolts/nuts by hand, and then move aside the ignition coil capacitor. Deposits may adhere the manifold to the cylinder heads and it may be necessary to exert some pressure to separate the two with pry bars but refrain from using pry bars to prise between the manifold and the cylinder heads as this may cause significant damage. Flip over the manifold, the pull out the heater supply tube and then change the O-ring with a new one. Scrape of all the remains of the gasket and sealant deposits on the manifold and cylinder heads and clean the mating areas. RTV sealer should then be applied around the front and rear cylinder head water passages before putting down the new gaskets, RTV sealer should also be applied around each of the manifold side of the gasket where the water passages are. Adjust the manifold into its appropriate position over the cylinder heads' ports then fix the rail and the injectors onto the lower manifold and then the manifold mounting bolts with an ignition coil capacitor. Last but not the least, increasingly twist the nuts/bolts to allow more contact between either and the threads; this should also be done in a number of ratchets till the completion of operation is done in the sequence of the removal of the part. With the cooling system empty, refill it, start up the engine, crank it and check for fuel, vac and coolant leaks.