Liberty, Wrangler 2006-2007

Intake Manifold

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Removal & Installation



2.8L Diesel Engine
  1. Disconnect negative battery cable.
  2.  
  3. Remove engine cover and bracket.
  4.  
  5. Drain cooling system.
  6.  
  7. Evacuate A/C.
  8.  
  9. Remove radiator core support.
  10.  
  11. Remove cooling fan and fan drive viscous clutch assembly.
  12.  
  13. Remove accessory drive belt.
  14.  
  15. Remove accessory drive belt tensioner and both idler pulleys, Idler pulley bolts are L.H. thread.
  16.  
  17. Remove power steering pump pulley.
  18.  
  19. Remove front engine lift bracket.
  20.  
  21. Remove cooling fan support.
  22.  
  23. Remove generator and support bracketing.
  24.  
  25. Remove viscous heater.
  26.  
  27. Rotate the engine to 90 ° ATDC, or the 3 o-clock position at the crankshaft hub.
  28.  
  29. Remove vibration damper.
  30.  
  31. Disconnect main engine wiring harness connectors from right inner wheel housing.
  32.  
  33. Disconnect main engine wiring harness ancillary components and set harness aside.
  34.  
  35. Remove air cleaner housing.
  36.  
  37. Remove exhaust manifold heat shield .
  38.  
  39. Remove turbocharger heat shield retaining bolt and position shield aside .
  40.  
  41. Remove turbocharger oil supply line from turbocharger.
  42.  
  43. Raise and support vehicle.
  44.  
  45. Disconnect exhaust stabilizer bracket at lower exhaust manifold .
  46.  
  47. Disconnect exhaust system bracket at transmission cross member.
  48.  
  49. Lower the vehicle and remove the exhaust manifold retaining nuts.
  50.  
  51. Slide the exhaust manifold and turbocharger off of exhaust manifold studs .
  52.  
  53. Remove coolant hoses at thermostat housing.
  54.  
  55. Disconnect fuel return hose from fuel injectors and set aside.
  56.  
  57. Remove fuel injector pressure lines.
  58.  
  59. Disconnect fuel pump high pressure line at fuel rail.
  60.  
  61. Disconnect oil level indicator tube from intake manifold.
  62.  
  63. Disconnect brake booster line bracket from intake manifold and position aside.
  64.  
  65. Remove fuel injectors.
    CAUTION
    Before removing the cylinder head cover/ intake manifold or timing belt the crankshaft hub must placed at 90° ATDC or the 3 O-clock position. Failure to do so could result in valve and/or piston damage during reassembly.

  66.  
  67. Remove timing belt outer cover.
  68.  
  69. Remove timing belt.
  70.  
  71. Using VM.1085, remove both camshaft gears.
  72.  
  73. Remove timing belt inner cover.
  74.  
  75. Remove cylinder head cover/intake manifold.
  76.  

To install:

  1. Slide exhaust manifold and turbocharger on exhaust manifold studs .
  2.  
  3. Install exhaust manifold retaining nuts. Tighten the nuts to 27 ft. lbs. (36 Nm) in a cross sequence beginning in the middle and working outward, then perform the tightening sequence to the exhaust manifold nuts again.
  4.  
  5. Install exhaust manifold heat shield. Torque bolts to 217 inch lbs. (24.5 Nm).
  6.  
  7. Install turbocharger outlet to charge air cooler pipe.
  8.  
  9. Install upper radiator hose.
  10.  
  11. Install new cylinder head cover/intake manifold gasket.
  12.  
  13. Install cylinder head cover/intake manifold. Tighten the bolts as follows:
    1. Alternate between bolts 11 and 16 to seat cylinder head cover/intake manifold on cylinder head. Tighten the bolts to 62 inch lbs. (7 Nm).
    2.  
    3. Tighten all cylinder head cover/intake manifold retaining bolts to 18 ft. lbs. (25 Nm) in numerical order starting with 1 and ending with 16.

      Click image to see an enlarged view

      Fig. 2.8L engine cover bolt tightening sequence

    4.  

  14.  
  15. Install timing belt inner cover.
    NOTE
    Make sure the crankshaft is rotated to the 90 ° ATCD, or the 3 O-clock position.

  16.  
  17. Install both camshaft gears and tighten bolts finger tight.
  18.  
  19. Install timing belt.
  20.  
  21. Using VM.1085, torque cam gear retaining bolts to 108 Nm.
  22.  
  23. Install timing belt outer cover.
  24.  
  25. Remove both camshaft locking pins at this time.
  26.  
  27. Install fuel injectors.
  28.  
  29. Install brake booster line bracket to intake manifold.
  30.  
  31. Install oil level indicator tube to intake manifold.
  32.  
  33. Connect fuel pump high pressure line to fuel rail.
  34.  
  35. Install fuel injector pressure lines.
  36.  
  37. Connect fuel return hose to fuel injectors.
  38.  
  39. Connect engine coolant hoses to thermostat housing.
  40.  
  41. Raise vehicle.
  42.  
  43. Reconnect exhaust system bracket at transmission cross member.
  44.  
  45. Connect exhaust stabilizer bracket to lower exhaust manifold .
  46.  
  47. Install turbocharger oil supply line to turbocharger.
  48.  
  49. Lower vehicle.
  50.  
  51. Install turbocharger heat shield.
  52.  
  53. Install exhaust manifold heat shield.
  54.  
  55. Install air cleaner housing.
  56.  
  57. Install main engine wiring harness and connect all ancillary electrical components.
  58.  
  59. Install viscous heater.
  60.  
  61. Install vibration damper.
  62.  
  63. Install generator.
  64.  
  65. Install cooling fan support.
  66.  
  67. Install front engine lift bracket.
  68.  
  69. Install power steering pump pulley.
  70.  
  71. Install accessory drive belt tensioner and both idler pulleys. Idler pulley retaining bolts are L.H. Thread.
  72.  
  73. Install accessory drive belt.
  74.  
  75. Install cooling fan and fan drive viscous clutch assembly.
  76.  
  77. Install upper radiator core support.
  78.  
  79. Refill cooling system.
  80.  
  81. Install engine cover and bracket.
  82.  
  83. Connect negative battery cable.
  84.  
  85. Start engine and allow to warm. Turn engine off and inspect for leaks.
  86.  

3.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  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 engine

  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.  

 
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