Cherokee, Grand Cherokee, 1999-2005

Intake Manifold

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Removal & Installation



2.5L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accessory drive belt
     
    Power steering pump and brackets, if equipped
     
    Fuel line
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Fuel injector connectors
     
    Closed Crankcase Ventilation (CCV) system
     
    Manifold Absolute Pressure (MAP) sensor vacuum line
     
    Brake booster vacuum line
     
    Exhaust front pipe
     
    Intake manifold and discard the gaskets
     
    Exhaust manifold and discard the gaskets
     

  8.  

To install:

Click image to see an enlarged view

Fig. Manifold head torque sequence-2.5L engine

  1. Install or connect the following:

    New gasket over the locating dowels
     
    Exhaust manifold to the studs and tighten the nuts finger-tight
     

  2.  
  3. Install the intake manifold. Torque the fasteners in sequence as follows:
    1. Step 1: Bolt 1 to 30 ft. lbs. (41 Nm).
    2.  
    3. Step 2: Fasteners 2-7 to 23 ft. lbs. (31 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Exhaust front pipe
     
    Brake booster vacuum line
     
    MAP sensor vacuum line
     
    CCV system
     
    Fuel injector connectors
     
    HO 2 S sensor connector
     
    IAT sensor connector
     
    ECT sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Fuel line
     
    Power steering pump and brackets, if equipped
     
    Accessory drive belt
     
    Air intake hose
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

3.7L & 4.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accelerator cable
     
    Cruise control cable
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Cruise control servo hose
     
    Accessory drive belt
     
    Alternator
     
    A/C compressor
     
    Engine ground straps
     
    Ignition coil towers
     
    Oil dipstick tube
     
    Fuel line
     
    Fuel supply manifold
     
    Throttle body and mounting bracket
     
    Cowl seal
     
    Right engine lifting stud
     
    Intake manifold. Remove the fasteners in reverse of the tightening sequence.
     

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.7 & 4.7L engines

  1. Install or connect the following:

    Intake manifold using new gaskets. Torque the bolts, in sequence, to 105 inch lbs. (12 Nm).
     
    Right engine lifting stud
     
    Cowl seal
     
    Throttle body and mounting bracket
     
    Fuel supply manifold
     
    Fuel line
     
    Oil dipstick tube
     
    Ignition coil towers
     
    Engine ground straps
     
    A/C compressor
     
    Alternator
     
    Accessory drive belt
     
    Cruise control servo hose
     
    Brake booster vacuum line
     
    Canister purge vacuum line
     
    PCV valve and hose
     
    ECT sensor
     
    IAC valve connector
     
    TP sensor connector
     
    IAT sensor connector
     
    MAP sensor connector
     
    Cruise control cable
     
    Accelerator cable
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Fill and bleed the cooling system.
  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

4.0L Engine

NOTE
The engine intake and exhaust manifold must be removed and installed together. The manifolds use a common gasket at the cylinder head.

  1. Disconnect the battery negative cable.
  2.  
  3. Remove air cleaner inlet hose from throttle body assembly.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the throttle cable, vehicle speed control cable (if equipped) and the transmission line pressure cable.
  8.  
  9. Disconnect the following electrical connections and secure their harness out of the way:

    Throttle Position Sensor
     
    Idle Air Control Motor
     
    Coolant Temperature Sensor (at thermostat housing)
     
    Intake Air Temperature Sensor
     
    Oxygen Sensor
     
    Crank Position Sensor
     
    Six Fuel Injector Connectors
     

  10.  
  11. Disconnect the map sensor, HVAC, and brake booster vacuum supply hoses at the intake manifold.
  12.  
  13. Perform the fuel pressure release procedure.
  14.  
  15. Disconnect and remove the fuel system supply line from the fuel rail assembly.
  16.  
  17. Loosen the accessory drive belt. Loosen the tensioner.
  18.  
  19. Remove the power steering pump and bracket from the intake manifold and set aside.
  20.  
  21. Raise the vehicle.
  22.  
  23. Disconnect the exhaust pipe from the engine exhaust manifold. Discard the seal.
  24.  
  25. Lower the vehicle.
  26.  
  27. Remove the intake manifold and engine exhaust manifold.
  28.  

To install:

  1. If the manifold is being replaced, ensure all the fitting, etc. are transferred to the replacement manifold.
  2.  
  3. Install a new engine exhaust/intake manifold gasket over the alignment dowels on the cylinder head.
  4.  
  5. Position the engine exhaust manifold to the cylinder head. Install fastener Number 3 and finger tighten at this time
  6.  
  7. Install intake manifold on the cylinder head dowels.
  8.  
  9. Install washer and fastener Numbers 1, 2, 4, 5, 8, 9, 10 and 11.
  10.  
  11. Install washer and fastener Numbers 6 and 7.
  12.  
  13. Tighten the fasteners in sequence and to the specified torque.

    Click image to see an enlarged view

    Fig. The intake and exhaust manifolds torque sequence for the 1999-01 models

  14.  
  15. Fastener Numbers 1 through 5 - Tighten to 24 ft. lbs. (33 Nm).
  16.  
  17. Fastener Numbers 6 and 7 - Tighten to 23 ft. lbs. (31 Nm).
  18.  
  19. Fastener Numbers 8 through 11 - Tighten to 24 ft. lbs. (33 Nm)
  20.  
  21. Install the power steering pump and bracket to the intake manifold. Tighten the belt to specification.
  22.  
  23. Install the fuel system supply line to the fuel rail assembly. Before connecting the fuel supply line to the fuel rail inspect the O-rings and replace if necessary.
  24.  
  25. System for the correct procedure.
  26.  
  27. Connect all electrical connections on the intake manifold.
  28.  
  29. Connect the vacuum hoses previously removed.
  30.  
  31. Install throttle cable, vehicle speed control cable (if equipped)
  32.  
  33. Install the transmission line pressure cable (if equipped)
  34.  
  35. Install air cleaner assembly.
  36.  
  37. Connect air inlet hose to the throttle body assembly.
  38.  
  39. Raise the vehicle.
  40.  
  41. Using a new exhaust manifold seal, connect the exhaust pipe to the engine exhaust manifold. Tighten the bolts to 23 ft. lbs. (31 Nm).
  42.  
  43. Lower the vehicle.
  44.  
  45. Connect the battery negative cable.
  46.  
  47. Start the engine and check for leaks.
  48.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accessory drive belt
     
    Power steering pump and brackets, if equipped
     
    Fuel line
     
    Fuel injector connectors
     
    Fuel supply manifold and injectors
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Closed Crankcase Ventilation (CCV) system
     
    Manifold Absolute Pressure (MAP) sensor vacuum line
     
    Brake booster vacuum line
     
    Exhaust front pipe
     
    Intake and exhaust manifolds and discard the gaskets
     

  8.  

To install:

  1. Install or connect the following:

    New gasket over the locating dowels
     
    Exhaust manifold to the studs and tighten the nuts finger-tight

    Click image to see an enlarged view

    Fig. Manifold torque sequence-2002-04 4.0L engine

     

  2.  
  3. Install the intake manifold. Torque the fasteners in sequence as follows:
    1. Step 1: Fasteners 1-5 to 30 ft. lbs. (41 Nm).
    2.  
    3. Step 2: Fasteners 6 and 7 to 23 ft. lbs. (31 Nm).
    4.  
    5. Step 3: Fasteners 8-11 to 24 ft. lbs. (33 Nm)
    6.  

  4.  
  5. Install or connect the following:

    Exhaust front pipe
     
    Brake booster vacuum line
     
    MAP sensor vacuum line
     
    CCV system
     
    HO 2 S sensor connector
     
    IAT sensor connector
     
    ECT sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Fuel supply manifold and injectors
     
    Fuel injector connectors
     
    Fuel line
     
    Power steering pump and brackets, if equipped
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

5.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove engine cover.
  4.  
  5. Bleed fuel system.
  6.  
  7. Disconnect negative cable from battery.
  8.  
  9. Remove air inlet hose.
  10.  
  11. Remove ignition wires from on top of intake manifold.
  12.  
  13. Disconnect electrical connectors for the following components:

    Manifold Absolute Pressure (MAP) Sensor
     
    Fuel Injectors
     
    ETC (Electric Throttle Control)
     

  14.  
  15. Remove wire harness from intake manifold.
  16.  
  17. Disconnect brake booster hose, purge hose, and MUA hose (Make Up Air Hose).
  18.  
  19. Remove EGR tube from intake manifold.
  20.  
  21. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts.
  22.  
  23. Remove intake manifold as an assembly.
    NOTE
    There is no approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced.


    NOTE
    Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.

  24.  
  25. Inspect the intake sealing surface for cracks, nicks and distortion.
  26.  
  27. Inspect the intake manifold vacuum hose fittings for looseness or blockage.
  28.  

To install:

  1. Position intake manifold.
  2.  
  3. Install intake manifold retaining bolts, and tighten from the middle bolts towards the outside in a criss-cross pattern. Torque fasteners to 105 inch lbs. (12 Nm).
  4.  
  5. Install EGR tube.
  6.  
  7. Install wire harness on intake manifold.
  8.  
  9. Connect electrical connectors for the following components:

    Manifold Absolute Pressure (MAP) Sensor
     
    Fuel Injectors
     
    ETC (Electronic Throttle Control)
     

  10.  
  11. Install ignition wires.
  12.  
  13. Connect Brake booster hose, purge hose, and MUA hose (Make Up Air hose).
  14.  
  15. Install air inlet hose.
  16.  
  17. Connect negative cable to battery.
  18.  
  19. Install engine cover.
  20.  

 
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