Jeep 5184199AF Intake Manifold

Before replacing the upper intake manifold, turn off the fuel pump and remove the negative terminal from the remote ground system. Release and label the vacuum hoses and connectors at the upper intake manifold and throttle body and ETC wiring harness, then remove the air intake duct and air filter housing. Then, further remove the EGR pipe and the upper intake manifold support brackets and then loosen the manifold bolts in the reverse sequence that you tightened them; consequently, you can then take off the manifold and the foam insulator pad. The sealing surfaces and gaskets should be clean and inspected with a view of replacing the bad ones while retaining the serviceable ones. Place and secure the upper intake manifold to the lower intake manifold with the help of bolts, and turn them in the correct order. With regard to the lower intake manifold, at least initially, remove the upper intake manifold; label and disconnect any other hoses that may be in the way. Disconnect fuel rail and injectors, unbolt lower intake manifold as far as possible and then come off in turn, do not use forceful pressure between the manifold and the heads to check the gasket sealing surfaces. Ensure that the sealing surfaces' and gasket condition is okay and replace those that are badly affected. Place the lower intake manifold over the engine and make sure there are proper mating surfaces with the gaskets, install the fuel rail and the injectors. For clearance, leave the fuel rail retaining bolts to be half tightened to facilitate alignment, while tighten all the remaining lower intake manifold bolts in several passes in the sequence recommended above. Lastly, engage the engine turn it on and look for any fuel, vacuum, and coolant leaks.

To perform removal of the throttle body assembly and intake manifold together with the exhaust manifolds, it is necessary first of all to release the fuel system pressure and disconnect the negative terminal of the battery and to drain the cooling system. Next, discard the air cleaner, be sure to identify all the vacuum lines and loose them from their connectors, all electrical wires, and fuel lines and the accelerator cable from the throttle lever. If so provisioned, remove the power steering pump belt, then disconnect the power brake vacuum line to the intake manifold, then unscrew the water hoses from the coolant crossover. Lift the front part of the car with jack and fix it securely on jack stands; remove the exhaust pipe from the exhaust manifold. If fitted, unbolt the power steering pump and, with it out of the way, set aside, and then unbolt the intake manifold support bracket and sever the EGR tube from the exhaust manifold. Lose the intake manifold bolts, lower the car and unbolt the throttle body and intake manifold in one assembly, thereby detaching the throttle body and gasket from the intake manifold before placing the unit on the bench. Lose the exhaust manifold nuts and take off the exhaust manifold: dispose of old gaskets and clean all gasket contact areas. Manifolds should also be cleaned with solvent and dried by compressed air, and the mating surfaces should be examined flat in relation to the straightedge, feeler gauges and the manifolds themselves should be examined for cracks and distortion and if present they should either be replaced or resurfaced. Concerning installation, it is advisable to replace either manifold; if so, transfer the studs to the new manifold. For the SOHC apply a thin layer of gasket sealant then place the new gaskets on the manifold sides, place the exhaust manifold on the cylinder head then install the nuts and begin tightening at the center in a cross wise manner. Place the intake manifold on the head, lift the car and secure it properly on jack stands, using the new intake manifold bolts put them in loosely following the crisscross technique beginning at the middle. The rest of the procedure of installation is carried out in the reverse order to the removal procedure.

The intake manifold is made of aluminum and has two parts, the upper and lower one; the upper intake manifold is enough to remove only when some work on spark plugs or valve cover is to be done. To achieve complete removal the fuel system pressure has to be discharged, the negative terminal has to be loosened. The bolts of Intake Air Temperature sensor need to be removed and the electrical connector needs to be disconnected and the tube for the air intake and the upper housing of the air filter. Also, electrical connectors at the IAC motor, TPS, and MAP sensor must be disconnected, as well as vacuum hoses from several parts. The accelerator cable as well as the cruise control and transmission control cables, if installed, must be disconnected. To replace or repair the EGR pipe the EGR pipe is disconnected with the EGR valve and also with the intake manifold by just unbolt it and then the oil dipstick is removed. When the upper and the lower intake manifolds are removed as a unit then the subsequent procedures include the detaching of the electrical connector to the Coolant Temperature Sensor, fuel injector harness connectors in addition to the fuel rail, pressure regulator and injectors assembly. This part should be removed when replacing servicing the intake manifold plenum, however; it can stay on if not necessary. To remove the intake manifold and its gasket, a number of bolts holding the intake manifold support bracket and the intake manifold bolts and washers are required. For inspection the straightedge and feeler gauge should be employed to check for warpage on the mating surfaces of the intake manifold and cylinder head and if this is greater than specified limits, the intake manifold or cylinder head must be resurfaced or replaced. A new manifold gasket should be installed when the manifold is being installed and the intake manifold bolts should be tightened to specification in a star pattern with the remainder of the installation in the reverse of the removal process.

Disconnect the negative cable from the battery, remove the air filter housing and the accelerator cable, and for models with automatic transmission, disconnect the transmission line pressure cable. Detach the cruise control cable if equipped, then disconnect the vacuum connector on the intake manifold by lifting the connector assembly up and out of the bracket and pulling it apart. Label and disconnect all vacuum and electrical connectors on the intake manifold, relieve the fuel pressure, and disconnect the fuel supply and return lines from the fuel rail assembly, capping the open ends. Loosen the serpentine drive belt, remove the power steering pump and bracket from the intake manifold without disconnecting the hoses, and ensure the pump remains upright to prevent fluid spillage. Remove the fuel rail and injectors, then take off the intake manifold heat shield by removing the bolts. Unscrew the intake manifold bolts, noting that four can be accessed from the top while the remaining four require reaching below the manifold. Remove the EGR tube from the intake manifold, pull the manifold slightly away from the engine to disengage it from the locating dowels, and lift it out of the engine compartment. Remove the exhaust manifold, as both manifolds share a common gasket, and thoroughly clean the gasket mating surfaces to eliminate all traces of old gasket material. If replacing the manifold, ensure all fittings are transferred to the new one, position a new gasket on the cylinder head using the locating dowels, and install the exhaust manifold, hand-tightening the nuts. Loosely position the intake manifold on the cylinder head, install the EGR tube between the manifolds, and then install the manifold retaining bolts, tightening all fasteners in the specified sequence. Reinstall the remaining parts in reverse order of removal, and before connecting the fuel lines to the fuel rail, replace the O-rings in the quick-connect fuel line couplings. Finally, run the engine and check for leaks.