Mopar 53034181AB Engine Intake Manifold

To release the components, the following steps have to be followed, firstly, the cowl cover has to be detached, then the cowl support brace and finally the windshield wiper motor support bracket. Stand back from the fuel pump and release the pressure off the fuel system and remove the connection of the negative terminal of the car battery. Then, take out the air filter housing and intake air duct and at least, unbolt the ignition coils. Remove the brake booster vacuum hose and the PCV hose and then remove fuel rail and the injector assembly. Remove the alternator and the air conditioning compressor, so that they are not connected anymore with the refrigerant lines, but still at hand. Remove the electrical connections from the IAT, MAP, TPS and ECT sensor leads. First unravel the intake manifold bolts from the external to the internal starting a 1/4 turn at one time until it could be easily unstucked, remove the intake manifold where any elements sticking to it will have to be detached as the intake manifold is pulled off. For installation; make sure that the surfaces of the cylinder heads as well as the intake manifold surfaces of the engine are clean. Any signs of wear on the O-rings on the intake manifold go for a new set of one but make sure to fit correctly. Gently install the manifold in position without shifting the rubber rings or coming into contact with the cylinder heads after placing it in position as this will shift the rings and this will cause vacuum or oil leakage. Torque the intake manifold bolts in the proper sequence to the manufacturer-prescribed LB of force. Last, do the remaining installation procedures in sequence with removal, engage the engine and look for vacuum leaks especially at the intake manifold gasket.

To accomplish the removal of the lower intake manifold, the fuel system pressure must be released and the cable of the negative terminal of the battery disconnected. If equipped, remove the engine cover and, if necessary, drain the cooling system. Third, remove the electrical connectors from the electronic throttle body's, IAT sensor, the MAP sensor, and unbend the clamp then remove the hose connecting the throttle body and air-filter housing. Remove the PCV valve hose from the intake manifold, EVAP purge solenoid line, power brake booster connector hoses and the EGR hose. To gain access the wiring harness relocate it by removing the retainers from intake support brackets next remove the bolts for intake manifold support brackets and upper intake manifold bolts to raise the upper manifold off the lower. Seal the intake ports with covers in order to minimize and hinder the penetration of dust in the engine. Take off the upper radiator hose from the thermostat housing, further, remove the upper intake manifold. Remove the electrical connectors from fuel injector, coolant temperature sensor, and knock sensor; and remove the heater hose from the intake manifold, and the coolant overflow hose from the thermostat housing. Turn the fuel line off, and then take off the fuel rail combined with the injectors. Last, take out the lower intake manifold bolts and followed by the elimination of the lower intake manifold. For installation, it is necessary to have clean surfaces of the mating of the cylinder heads, cylinder block as well as the intake manifold using gasket removal solvents where necessary. Old gasket material has to be scraped off with a gasket scraper and the flange surfaces clean with lacquer thinner or acetone with no residues being left in the intake ports. Deposit a 1/4 inch bead of RTV sealant on the surfaces of the cylinder head that is going to be in contact with the engine block, place the lower intake gaskets in the right positions and lower down the lower intake manifold gently and then tightening the bolts of the manifold with your fingers and subsequently using the prescribed torque. The supply and exhaust hoses and harnesses can then be reconnected in the reverse of this sequence, fitting of a new upper-manifold gasket, the upper intake manifold to the lower intake manifold, then the bolts for the upper intake manifold can be tightened in a star pattern to the torque specification. Perform the final stages of installation of the remaining parts in the reverse order and if the cooling system was opened it has to be refilled, then just turn on the engine to detect any possible leaks or improper work.

In order to take out the intake manifold, one has to relieve the fuel pressure and then loosen the cable from the negative terminal of the battery. Then, unbolt the air intake duct from the throttle body and also cap and tag the vacuum lines for the PCV valve and the power brake booster, the cruise control servo and the evaporative emission control. Remove bulb sockets from respective sockets for the various sensors, ignition coils, and Idle Air Control motor, and also for the alternator and air conditioning compressor. Remove the ground straps that are fastened to the intake manifold and throttle body; then remove the nut of the engine oil dipstick as well as the dipstick tube from the engine block. Disconnect the throttle and cruise control cable from the throttle body and bracket and ignition coils. Place the fuel rails, the throttle body and the mounting bracket aside and siphon the coolant as well as pull the heater hoses. Take the coolant temperature sensor out of the way and, on 2007 and later models, snap the EGR tube. Unbolt the intake manifold coming in their order, but be very careful not to scratch the gasket flares. Disconnect and remove any hose labels that are still connected to the manifold and get rid of any hoses that might hinder the process then lift the manifold and take it off the engine. For installation, clean and check the condition of the intake manifold and gaskets if they are worn out or damaged they should be replaced. Set the manifold to the engine in a manner that is correct and then screw in the nuts and bolts until it is just slightly tight. Then, based on the above tightening sequence, tighten the bolts to the prescribed torque. To complete the procedure reverse the above steps of removal, refill the cooling system, engage the engine, and examine for signs of leakage.

The intake manifold is made from aluminum and is in two parts; the upper section only needs to be detached if the spark plugs or valve cover have to be accessed and not the whole intake manifold. Among things one needs to do when the complete intake manifold is pulled off is to depressurize the fuel system, though the upper manifold removal let's you skip the process. The first step is to remove the negative battery terminal cable, after that the Electrical Connector of Intake Air Temperature Sensor, thereafter the Air Intake Tube and Air Filter Upper Housing is to be removed. Subsequently, remove the electrical connectors at the Idle Air Control motor, Throttle Position Signal output unit, and Manifold Absolute Pressure sensing point; as well as the vacuum lines from numerous parts. Accelerator cable as well as, if the car has one, the cruise control and transmission control cables must be disconnected. Bolts on the EGR pipe on the EGR valve and intake manifold must be taken out together with the oil dipstick. If only upper intake manifold is being removed it is required to undo manifold support bracket bolt, uncouple the upper intake manifold attaching bolt, and lift the manifold off. Another manifold gasket is to be applied when refitting, before tightening the bolts, the central ones first, apply uniform and progressive force. More specifically, for full intake manifold removal, the Coolant Temperature Sensor electrical connector has to be disconnected, as well as the fuel injector harness connectors, fuel rail, fuel pressure regulator and, finally, the fuel injectors which have to be removed as a single piece. If changing or reading the intake manifold plenum, the throttle body should be taken off; but if only changing the cylinder head it can stay there. It is recommended that the intake manifold support bracket bolts and the intake manifold bolts and washers be removed and this would enable the intake manifold and gasket to be replaced. For inspection, straightedge and feeler gauge ought to be used on the mating surfaces in order to identify warpage and where warpage embraces limits, resurfacing or replacement is required. When bolting the manifold back, the intake manifold gasket should be new and the bolts tightened evenly starting with the inner ones to avoid warping of the manifold then the rest of it is the reverse of the process of removing the manifold.