Liberty, Wrangler 2006-2007

Combination Manifold

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Removal & Installation



4.0L Engine

NOTE
The intake and exhaust manifold is removed as an assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove air cleaner inlet hose from the resonator assembly.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the throttle cable, vehicle speed control cable (if equipped) and the transmission line pressure cable.
  10.  
  11. 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
     
    Manifold Absolute Pressure (MAP) Sensor.
     

  12.  
  13. Disconnect HVAC, and Brake Booster vacuum supply hoses at the intake manifold.
  14.  
  15. Perform the fuel pressure release procedure.
  16.  
  17. Disconnect and remove the fuel system supply line from the fuel rail assembly.
  18.  
  19. Remove the accessory drive belt.
  20.  
  21. Remove the power steering pump from the intake manifold and set aside.
  22.  
  23. Raise the vehicle.
  24.  
  25. Disconnect the exhaust pipes from the engine exhaust manifolds.
  26.  
  27. Lower the vehicle.
  28.  
  29. Remove the intake manifold and exhaust manifold bolts and manifolds.
  30.  

To install:

Click image to see an enlarged view

Fig. Manifold torque sequence-4.0L engine


NOTE
If the manifold is being replaced, ensure all the fittings, etc. are transferred to the replacement manifold.

  1. Install a new engine exhaust/intake manifold gasket over the alignment dowels on the cylinder head.
  2.  
  3. Position the engine exhaust manifolds to the cylinder head. Install fastener Number 3 and finger tighten at this time.
  4.  
  5. Install intake manifold on the cylinder head dowels.
  6.  
  7. Install washers and fasteners 1, 2, 4, 5, 8, 9, 10 and 11.
  8.  
  9. Install washers and fasteners 6 and 7.
  10.  
  11. Tighten the fasteners in sequence and to the specified torque.

    Fasteners 1 through 5: 24 ft. lbs. (33 Nm).
     
    Fasteners 6 and 7: Tighten to 23 ft. lbs. (31 Nm).
     
    Fasteners 8 through 11: 24 ft. lbs. (33 Nm).
     

  12.  
  13. Install the power steering pump to the intake manifold.
  14.  
  15. Install the accessory drive belt.
  16.  
  17. Install the fuel system supply line to the fuel rail assembly.
  18.  
  19. Connect all electrical connections on the intake manifold.
  20.  
  21. Connect the vacuum hoses previously removed.
  22.  
  23. Install throttle cable, vehicle speed control cable (if equipped).
  24.  
  25. Install the transmission line pressure cable (if equipped).
  26.  
  27. Install air cleaner assembly.
  28.  
  29. Connect air inlet hose to the resonator assembly.
  30.  
  31. Raise the vehicle.
  32.  
  33. Connect the exhaust pipes to the engine exhaust manifolds. Tighten the bolts to 23 ft. lbs. (31 Nm)
  34.  
  35. Lower the vehicle.
  36.  
  37. Connect the battery negative cable.
  38.  
  39. Start the engine and check for leaks.
  40.  

 
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