Mopar 4854197AA Intake Manifold

Disconnect the negative cable from the battery. Drain the cooling system. Remove the carburetor or throttle body. Label and then disconnect any wiring, hoses and control cables still connected to the intake manifold. Unbolt the power steering pump (if equipped), and set it aside without disconnecting the hoses. Disconnect the throttle valve (TV) linkage, if equipped with an automatic transmission. On 1984 through 1990 models, disconnect the EGR tube from the intake manifold. Remove the intake manifold bolts. Pull the manifold away from the engine slightly to disengage it from the dowel pins in the cylinder head, then lift the manifold from the engine. If the manifold sticks to the engine after all the bolts are removed, tap it with a soft face hammer or a block of wood and a hammer while supporting the manifold. Thoroughly clean the mating surfaces, removing all traces of gasket material. If the manifold is being replaced, transfer all fittings to the new one. Position the replacement gasket on the cylinder head and install the manifold. Install the intake manifold bolts and tighten them in several stages, following the sequence shown to the specified torque. Reinstall the remaining parts in the reverse order of removal. Run the engine and check for vacuum leaks and proper operation.

Disconnect the negative cable from the battery. Remove the air cleaner assembly and the throttle cable. On automatic transmission equipped models, disconnect the transmission line pressure (TV) cable. Detach the cruise control cable, if equipped. Disconnect the vacuum connector on the intake manifold by lifting the connector assembly up and out of the bracket and then pulling it apart. Label and then disconnect all vacuum and electrical connectors on the intake manifold. Relieve the fuel pressure and then disconnect the fuel supply and return lines from the fuel rail assembly. Cap the open ends. Loosen the serpentine drivebelt. Remove the power steering pump and bracket from the intake manifold and set it aside without disconnecting the hoses. Be sure to leave the pump in an upright position so fluid won't spill. Remove the fuel rail and injectors. Remove the intake manifold heat shield. Unbolt the intake manifold. Four of the intake manifold mounting bolts can be accessed from the top - you must reach below the manifold to remove the remaining four. Remove the EGR tube from the intake manifold. Pull the manifold away from the engine slightly to disengage it from the locating dowels in the cylinder head, then lift the manifold out of the engine compartment. Remove the exhaust manifold. This is necessary because the intake and exhaust manifolds share a common gasket. Thoroughly clean the gasket mating surfaces, removing all traces of old gasket material. If the manifold is being replaced, make sure all the fittings, etc. are transferred to the replacement manifold. Position a new gasket on the cylinder head, using the locating dowels to hold it in place. Install the exhaust manifold and hand tighten the nuts. Position the intake manifold loosely on the cylinder head. Install the EGR tube between the manifolds. Install the manifold retaining bolts and tighten all fasteners in sequence to the specified torque. Note that nut number one (1) requires a greater torque than the others. Reinstall the remaining parts in the reverse order of removal. Run the engine and check for fuel, vacuum and exhaust leaks.