Lower Intake Manifold

REMOVAL- LOWER INTAKE MANIFOLD
1. Perform fuel system pressure release procedure (before attempting any repairs).
2. Drain the cooling system.
3. Remove the upper intake manifold.
4. Remove the fuel line.

Fig.125:

5. Remove ignition coil and bracket (Fig. 125).

Fig.126:

6. Disconnect heater supply hose and engine coolant temperature sensor (Fig. 126).
7. Disconnect the fuel injector wire harness.
8. Remove the fuel injectors and rail assembly (Fig. 125).
9. Remove radiator upper hose.
10. Remove the intake manifold bolts.

Fig.127:

11. Remove lower intake manifold (Fig. 127).

WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.

12. Remove intake manifold seal retainers screws (Fig. 127). Remove intake manifold gasket.
13. Inspect and clean manifold.

CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.

INSPECTION
Check for:
- Damage and cracks of each section.
- Clogged water passages in end cross-overs (if equipped).
- Check for cylinder head mounting surface distortion using a straightedge and thickness gauge.

INSTALLATION - LOWER INTAKE MANIFOLD

Fig.128:

1. Place a bead (approximately 1/4 inch diameter) of Mopar Engine RTV GEN II onto each of the four manifold to cylinder head gasket corners (Fig. 128).
2. Carefully install the new intake manifold gasket (Fig. 127). Tighten end seal retainer screws to 12 Nm (105 in. lbs.).

Fig.129:

3. Install lower intake manifold (Fig. 127). Install the bolts and torque to 1 Nm (10 in. lbs.). Then torque bolts to 22 Nm (200 in. lbs.) in sequence shown in (Fig. 129). Then torque again to 22 Nm (200 in. lbs.). After intake manifold is in place, inspect to make sure seals are in place.
4. Install the fuel injectors and rail assembly.
5. Connect fuel injector electrical harness.
6. Connect the engine coolant temperature sensor (Fig. 126).
7. Connect the heater supply (Fig. 126) and radiator upper hoses to manifold.
8. Connect the fuel line.
9. Install the upper intake manifold.
10. Connect negative battery cable.
11. Fill the cooling system.