Intake Manifold

Removal & Installation

CAUTION
Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.

Upper Intake Manifold

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the air cleaner outlet pipe and accelerator cable snow shield.
4. Disconnect the accelerator cable from the speed control actuator cable, if present.
5. Loosen the bolt and slide the engine control wiring connector off of the bracket.

   NOTE: The spark plug wires need to be connected to the correct ignition coil terminal. Before removing the spark plug wires, mark them for correct placement at installation.

6. Disconnect the spark plug wires from the ignition coil.
7. Disconnect the electrical connectors for the ignition coil and radio ignition interference capacitor.
8. Disconnect the electrical connectors for the throttle position (TP) sensor and the idle air control (IAC).
9. Disconnect the brake booster vacuum hose, the positive crankcase ventilation (PCV) hose, and the vacuum hose.
10. Disconnect the canister purge line from the throttle body.
11. Remove the intake manifold nuts and fuel line bracket.
12. Remove the upper intake manifold and gasket. If necessary, install new gaskets.

To Install:

1. Correctly place the upper intake manifold.
2. Put the fuel line bracket in place.
3. Install the intake manifold nuts and tighten in the sequence shown. Torque to 17 ft-lb (23 Nm).

   Upper intake manifold bolt torque sequence (4.0L)

4. Connect the canister purge line to the throttle body.
5. Connect the brake vacuum booster hose, the PCV hose, and the vacuum hose.
6. Connect the electrical connector for the IAC valve, the TP sensor, the ignition coil, and the radio ignition interference capacitor.

   CAUTION
   The spark plug wires must be installed correctly for the vehicle to operate properly.

   NOTE: Before installation, wipe the spark plug wires with a clean cloth.

   NOTE: Whenever a spark plug wire is removed from a spark plug or ignition coil, or when a new spark plug wire is installed, before installation you must apply silicone brake caliper grease and dielectric compound (D7AZ-19A331-A) to the spark plug wire boot.

7. Connect the spark plug wires to the ignition coil.
8. Slide the engine sensor control wiring connector onto the bracket. Torque to 53 in-lb (6 Nm).
9. Connect the accelerator cable to the speed control actuator cable, if present.
10. Install the accelerator cable snow shield and the air cleaner outlet tube.
11. Connect the negative battery cable.
12. Start the vehicle and check for leaks, repair if necessary.

Lower Intake Manifold

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.
3. Remove the valve covers and disconnect the fuel line.
4. Remove the water thermostat.
5. Disconnect the electrical connectors for the fuel injector and the water temperature sender.
6. Disconnect the engine coolant temperature (ECT) sensor.
7. Remove the intake manifold and gasket.

To Install:

1. Clean and inspect the mating surfaces.
2. Apply a bead of silicone gasket and sealant at the four cylinder block-to-cylinder head parting lines.
3. Install the gasket and intake manifold. Tighten the bolts in 4 steps according to the sequence shown.
   • Step 1: Torque to 27 in-lb (3 Nm).
   • Step 2: Torque to 89 in-lb (10 Nm).
   • Step 3: Torque to 10 ft-lb (13 Nm).
   • Step 4: Torque to 12 ft-lb (16 Nm).

   Lower intake manifold bolt torque sequence (4.0L)

4. Connect the ECT sensor, and the electrical connectors for the water temperature sender.
5. Connect the electrical connectors for the fuel injector.
6. Install the water thermostat.
7. Connect the fuel line.
8. Install the valve covers.