Manifold, Intake: Removal: Upper

WARNING: This page is about a different variant/trim than selected.

Fig 1: Negative Battery Cable

Courtesy of CHRYSLER GROUP, LLC

Disconnect and isolate the negative battery cable (1).

Fig 2: Engine Cover
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Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).

Fig 3: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose Assembly & Fasteners
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Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.
Loosen the clamp (2) at the throttle body.
Loosen the clamp (3) at the air cleaner housing.
Lift the air inlet hose assembly retaining grommet off the ball stud (4).
Remove the air inlet hose assembly (5).

Fig 4: Brake Booster Hose Retainer
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Disengage the brake booster hose retainer (1) from the upper intake manifold.

Fig 5: MAP Sensor, ETC, PCV Hose, Brake Booster Vacuum Hose, EVAP Vapor Purge Line, Clip & Wire Harness Retainer
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Disconnect the electrical connectors from the Manifold Absolute Pressure (MAP) sensor (2) and the Electronic Throttle Control (ETC) (4).
Disengage the ETC harness from the clip (5) on the throttle body and unfasten the wire harness retainer (1) from the upper intake manifold near the MAP sensor and reposition the wire harness.
Disconnect the following hoses from the upper intake manifold:
- Positive Crankcase Ventilation (PCV) (7)
- Brake booster vacuum hose (6)
- EVAP vapor purge line (3)
Fig 6: Upper Intake Manifold Support Bracket, Stud & Fasteners
Courtesy of CHRYSLER GROUP, LLC
Unfasten the wire harness retainer (4) from the upper intake manifold support bracket (2) stud retainer (3).
Remove the two nuts (1), loosen the stud (3) and reposition the upper intake manifold support bracket (2).

Fig 7: Heater Core Return Tube Upper Support Bracket Retaining Nut & Tube
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Remove the heater core return tube upper support bracket retaining nut (2) and reposition tube (1).

Fig 8: Nuts, Stud Retainers & Upper Intake Manifold Support Brackets
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Remove the two nuts (1), loosen two stud retainers (3) and reposition the two upper intake manifold support brackets (2).

Fig 9: Upper Intake Manifold & Bolts
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NOTE:
The upper intake manifold attaching bolts are captured in the upper intake manifold. Once loosened, the bolts will have to be lifted out of the lower intake manifold and held while removing the upper intake manifold.

NOTE:
Exercise care not to inadvertently loosen the two fuel rail attachment bolts that are in close proximity of the upper intake manifold attaching bolts.
Remove the seven manifold attaching bolts (1) and remove the upper intake manifold (2).

Fig 10: Intake Ports, Insulator & Alignment Posts
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Remove and discard the six upper to lower intake manifold seals (1).
Cover the open intake ports to prevent debris from entering the engine.
If required, remove the insulator (2) from the left cylinder head cover.