Intake Manifold-5.2L Engine - Jeep 1996 Grand Cherokee Service Manual

ZJ
REMOVAL AND INSTALLATION (Continued)
(9) Install the fuel system supply and return lines
to the fuel rail assembly. Before connecting the
fuel system lines to the fuel rail replace the
O-rings in the quick-connect fuel line cou-
plings. Refer to Group 14, Fuel System for the
proper procedure.
(10) Connect all electrical connections on the
intake manifold.
(11) Connect the vacuum connector on the intake
manifold and install it in the bracket.
(12) Install throttle cable, vehicle speed control
cable (if equipped).
(13) Install the transmission line pressure cable (if
equipped). Refer to Group 21, Transmission for the
adjustment procedures.
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the throttle plate
assembly.
(16) Raise the vehicle on a side mounted hoist.
(17) Use a new engine exhaust manifold seal. Con-
nect the exhaust pipe to the engine exhaust mani-
fold.
(18) Lower the vehicle.
(19) Connect the negative cable to the battery.
(20) Start the engine and check for leaks.
INTAKE MANIFOLD—5.2L ENGINE
REMOVAL
The aluminum intake manifold is a single plane
design with equal length runners. The manifold is
sealed by flange side gaskets with front and rear
cross-over gaskets. The intake manifold has internal
EGR.
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
(3) Remove the generator (refer to Group 8B Bat-
tery/Starting/Charging Systems).
(4) Remove the air cleaner.
(5) Remove the fuel lines and fuel rail (refer to
Group 14, Fuel System).
(6) Disconnect the accelerator linkage and, if so
equipped, the speed control and transmission kick-
down cables.
(7) Remove the return spring.
(8) Remove the distributor cap and wires.
(9) Disconnect the coil wires.
(10) Disconnect the heat indicator sending unit
wire.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems.
(13) Remove the A/C compressor bolts and set the
compressor on the fan shroud.
(14) Remove the support bracket from the intake
manifold and the mounting bracket.
EXHAUST SYSTEM AND INTAKE MANIFOLD
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold. Discard the
throttle body gasket.
(19) Remove the plenum pan as follows:
(a) Turn the intake manifold upside down. Sup-
port the manifold.
(b) Remove the bolts and lift the pan off the
manifold. Discard the gasket.
INSTALLATION
(1) Install the plenum pan, if removed, as follows:
(a) Turn the intake manifold upside down. Sup-
port the manifold.
(b) Place a new plenum pan gasket onto the seal
rail of the intake manifold. Position the pan over
the gasket. Align all the gasket and pan holes with
the intake manifold.
(c) Hand start all bolts.
(d) Tighten the bolts, in sequence (Fig. 12), as
follows:
Fig. 12 Plenum Pan Bolt Tightening Sequence
• Step 1—Tighten bolts to 2.7 N·m (24 in. lbs.)
torque.
• Step 2—Tighten bolts to 5.4 N·m (48 in. lbs.)
torque.
• Step 3—Tighten bolts to 9.5 N·m (84 in. lbs.)
torque.
• Step 4—Check that all bolts are tighten to 9.5
N·m (84 in. lbs.) torque.
11 - 7