Jeep Wagoneer/Commando/Cherokee 1957-1983 Repair Information

Intake Manifold

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REMOVAL & INSTALLATION 4-134 Engine



The intake manifold is cast as an integral part of the head.

6-225 Engine See Figure 1

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Fig. Fig. 1: Intake manifold bolt tightening sequence 6 cyl-225 engine

  1. Drain the cooling system.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the crankcase vent hose, distributor vacuum hose, and the fuel line from the carburetor.
  2.  
  3. Disconnect the two distributor leads from the coil.
  4.  
  5. Disconnect the wire from the temperature sending unit.
  6.  
  7. Remove the ten cap bolts that hold the intake manifold to the cylinder head. They must be replaced in their original positions.
  8.  
  9. Remove the intake manifold assembly and gasket from the engine.
  10.  
  11. Reverse the above procedure for installation. Tighten the bolts to the correct torque, and in the proper sequence.
  12.  

6-226 Engine

The intake and exhaust manifolds are removed as a unit, then separated.

  1. Remove the engine cover and housing.
  2.  
  3. Remove the air cleaner and carburetor.
  4.  
  5. Disconnect the exhaust pipe at the manifold.
  6.  
  7. Unbolt and remove the manifolds.
  8.  
  9. Installation is the reverse of removal. Retainers are used under the retaining nuts on all studs except the top ends and lower center. Plain washer are used under these nuts. It is possible, if you're not careful, to install the manifold assembly so that it interferes with the fit of the valve chamber cover at the upper rear corner of the cover. Leakage would result in this case. Torque the nuts, from the center towards the ends, to 30-35 ft. lb.
  10.  

6-230 Engine

  1. Disconnect and tag any hoses, wires or cables attached to the manifold or carburetor.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the carburetor.
  6.  
  7. Remove the nut and lockwasher that attaches the manifold and dipstick tube to the lower center stud on the head.
  8.  
  9. Remove the dipstick and tube.
  10.  
  11. Support the manifold and remove the four remaining nuts and lockwashers that attach it to the head and manifold.
  12.  
  13. Discard the gasket and thoroughly clean the mating surfaces of the head and manifold.
  14.  
  15. Installation is the reverse of removal. Always use a new gasket. Note that the gasket overlaps the intake port openings slightly. This is a calculated overlap designed to assist in air/fuel distribution. Do not attempt to cut the gasket to make it larger. Torque the manifold nuts to 15-20 ft. lb.
  16.  

6-232 and 6-258 Engine See Figure 2

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Fig. Fig. 2: Intake manifold bolt tightening sequence 6 cyl-232 and 258 engines

The intake and exhaust manifold are mounted externally on the left side of the engine and are attached to the cylinder head. They are removed as a unit.

  1. Disconnect the negative battery cable. Remove the air cleaner and carburetor.
  2.  
  3. Disconnect the accelerator cable from the accelerator bellcrank.
  4.  
  5. Disconnect the PCV vacuum hose from the intake manifold. Remove the vacuum advance CTO valve vacuum hoses as required.
  6.  
  7. Disconnect the distributor vacuum hose and electrical wires at the TCS solenoid vacuum valves. If equipped, disconnect the CEC system coolant temperature sender wire connector on the intake manifold.
  8.  
  9. Remove the TCS solenoid vacuum valve and bracket from the intake manifold. In some cases it might not be necessary to remove the TCS unit.
  10.  
  11. Disconnect the EGR valve and back pressure sensor hoses. If equipped, disconnect the electric heater wire connector. Remove the carburetor from the vehicle.
  12.  
  13. Remove the power steering mounting bracket and pump and set it aside without disconnecting the hoses. Remove air pump, if equipped.
  14.  
  15. Remove the EGR valve and back pressure sensor. If equipped, remove air conditioning drive belt idler assembly from cylinder head.
  16.  
  17. Disconnect the exhaust pipe from the manifold flange. If equipped with automatic transmission disconnect the throttle valve linkage.
  18.  
  19. Remove the manifold attaching bolts, nuts and clamps.
  20.  
  21. Separate the intake manifold and exhaust manifold from the engine as an assembly, and discard the gasket.
  22.  
  23. If either manifold is to be replaced, they should be separated at the heat riser area.
  24.  
  25. Clean the mating surface of the manifolds and the cylinder head before replacing the manifolds. Replace them in reverse order of the above procedure with new gasket. Tighten the bolts and nuts to the specified torque in the sequence shown.
  26.  

8-304, 8-360 and 8-401 Engines See Figures 3 through 7

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Fig. Fig. 3: Unfasten the intake manifold retaining bolts, then ...



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Fig. Fig. 4: ... remove the intake manifold from the vehicle



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Fig. Fig. 5: Remove the intake manifold gasket



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Fig. Fig. 6: Disengage the spark plug wire from the coil



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Fig. Fig. 7: Tag and disengage the coil wires

  1. Drain the coolant from the radiator.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the spark plug wires. Remove the spark plug wire bracket from the valve covers, and the bypass valve bracket.
  4.  
  5. Disconnect the upper radiator hose and the bypass hose from the intake manifold.
  6.  
  7. Disconnect the ignition coil bracket and lay the coil aside.
  8.  
  9. Disconnect the TCS solenoid vacuum valve from the right side valve cover.
  10.  
  11. Disconnect all lines, hoses, linkages and wires from the carburetor and intake manifold and TCS components as required.
  12.  
  13. Disconnect the air delivery hoses at the air distribution manifolds.
  14.  
  15. Disconnect the bypass valve bracket and lay the valve and the bracket assembly, including the hoses, forward of the engine.
  16.  
  17. Remove the intake manifold after removing the cap bolts that hold it in place. Remove and discard the side gaskets and the end seals.
  18.  
  19. Clean the mating surfaces of the intake manifold and the cylinder head before replacing the intake manifold. Use new gaskets and tighten the cap bolts to the correct torque. Install in reverse order of the above procedure.
  20.  

There is no specified tightening sequence for the 8-304, 360 and 401 intake manifold. Begin at the center and work outward.

8-327 Engine

  1. Drain the cooling system.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air cleaner assembly.
  2.  
  3. Remove the distributor.
  4.  
  5. Disconnect the throttle linkage at the carburetor and the throttle cable bracket attached to the manifold.
  6.  
  7. Disconnect the fuel line at the carburetor inlet. Also remove the vacuum lines at the thermostatic vacuum switch, if so equipped.
  8.  
  9. Disconnect the vacuum lines, the coil and ignition primary leads.
  10.  
  11. Remove the cap screws, lockwashers, nuts, and flat washers that secure the intake manifold to the cylinder heads.
  12.  
  13. Lift the intake manifold and carburetor assembly from the engine and remove all traces of gasket material from the intake manifold, cylinder block and cylinder heads mating surfaces.
  14.  
  15. Install the intake manifold assembly on the engine in the reverse order of removal. Torque the intake manifold mounted bolts to the proper torque value.
  16.  

There is no specific tightening sequence for the intake manifold of the 8-327. Begin at the center and work outward.

8-350 Engine

  1. Drain the cooling system.
  2.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the carburetor air cleaner. Disconnect all tubes and hoses from the carburetor. Disconnect and remove the ignition coil.
  2.  
  3. Disconnect the temperature indicator wire from the sending unit.
  4.  
  5. Disconnect the accelerator and transmission linkage at the carburetor.
  6.  
  7. Slide the front thermostat bypass hose clamp back on the hose. Disconnect the upper radiator hose at the outlet.
  8.  
  9. Disconnect the heater hose at the temperature control valve inlet. Force the end of the hose down to allow the coolant to drain from the intake manifold.
  10.  
  11. Remove the intake manifold-to-head attaching bolts.
  12.  
  13. Remove the intake manifold and carburetor as an assembly, by sliding the assembly rearward to disengage the thermostat bypass hose from the water pump. Remove all traces of gasket material from the mating surfaces of the intake manifold and the cylinder heads and block.
  14.  
  15. Install the intake manifold in the reverse order of removal, tightening at the attaching bolts in the correct sequence and to the proper torque.
  16.  

 
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