Mopar 4591863AM Intake Manifold Plenum

Label and disconnect the vacuum hoses and electrical connectors attached to the upper intake manifold and throttle body, including the electronic throttle control system.

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.

The remaining installation steps are the reverse of removal. Start the engine and check carefully for vacuum leaks at the intake manifold joints.

Install the upper intake manifold onto the lower intake manifold, tightening the bolts to torque specifications, with the remainder of the installation being the reverse of removal.

Next, remove the air filter housing, label and disconnect the hoses and electrical connectors attached to the intake manifold and throttle body, and remove the bolts securing the EGR pipe to the upper intake manifold.

Disconnect the cable from the negative terminal of the battery, ensuring that on 2015 and later models with an Intelligent Battery Sensor, the IBS connector is disconnected first.

As a precaution, remove the fuel rails and injectors.