Mopar 4792184AE Lower Engine Intake Manifold

Loosen the lower intake manifold mounting bolts/nuts in reverse order until they can be removed by hand. Carefully break the gasket seal without prying between the manifold and the heads.

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.

Locate the fuel pump fuse or relay in the under-hood fuse box. With the engine off, remove the fuse/relay, then start and run the engine until it stalls. Crank the engine for a few more seconds to dissipate residual pressure.

Remove the ignition coils and, on 2005 models, the spark plug wires.