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(43) Fill crankcase with engine oil. Refer to LUBRICATION and MAINTENANCE for correct (44) Fill the cooling system with reusable coolant or new coolant Refer to COOLING SYSTEM. (45) Align the hood to the scribe marks. Install the hood. (46) Install the air cleaner assembly. cable. WARNING: USE EXTREME CAUTION WHEN THE (48) Start the engine, inspect for leaks and correct the fluid levels, as necessary. INTAKE AND EXHAUST MANIFOLD REMOVAL NOTE: THE ENGINE INTAKE AND EXHAUST MANI- MUST BE REMOVED AND INSTALLED TOGETHER. THE MANIFOLDS USE A COMMON (1) Disconnect the battery negative cable. body assembly. (3) Remove the air cleaner assembly. cable (if equipped) and the transmission line pres- (5) 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 (6) Fuel Injector Connectors Booster vacuum supply hoses at the intake manifold. (7) Perform the fuel pressure release procedure. (Refer to Group 14, Fuel Systems for correct proce- (8) Disconnect and remove the fuel system supply line from the fuel rail assembly. (Refer to Group 14, (9) Remove the accessory drive belt (refer to Group 7, Cooling System). Loosen the tensioner. (10) Remove the power steering pump and bracket from the intake manifold and set aside. (11) Raise the vehicle. exhaust manifolds. (13) Lower the vehicle. the intake manifold and engine exhaust manifolds. INSTALLATION If the manifold is being replaced, ensure all the fit- ting, etc. are transferred to the replacement mani- (1) Install a new engine exhaust/intake manifold gasket over the alignment dowels on the cylinder (2) Position the engine exhaust manifolds to the cylinder head. Install fastener Number 3 and finger (3) Install intake manifold on the cylinder head dowels. (4) Install washer and fastener Numbers 1, 2, 4, 5, 8, 9, 10 and 11 (Fig. 47). (5) Install washer and fastener Numbers 6 and 7 (Fig. 47). (6) Tighten the fasteners in sequence and to the specified torque (Fig. 47). • Fastener Numbers 1 through 5—Tighten to 33 N·m (24 ft. lbs.) torque. • Fastener Numbers 6 and 7—Tighten to 14 N·m (126 in. lbs.) torque. • Fastener Numbers 8 through 11—Tighten to 33 N·m (24 ft. lbs.) torque. (7) Install the power steering pump and bracket to the intake manifold. Tighten the belt to specification. (8) Install the fuel system supply line to the fuel rail assembly. Before connecting the fuel supply Fig. 47 Intake and Exhaust Manifolds—4.0L 9 - 34 4.0L ENGINE WJ REMOVAL AND INSTALLATION (Continued) |