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Manifold Replacement - 4.0L Jeep Cherokee

November 13, 2009 in Repair Manual by admin | No comments

How to Replace Exhaust Manifold and Intake ManifoldNew Accordion Styled Header

On the 4.0 L engine, both the Intake Manifold and the Exhaust Manifold are located on the left side of the engine and must be removed together.

Removal of Intake and Exhaust Manifold

  1. Disconnect the negative battery cable using a 3/8″ socket wrench.
  2. Remove the air cleaner assembly.
  3. Disconnect the accelerator cable, cruise control cable, if equipped and transmission line pressure cable.
  4. Disconnect all electrical connectors on the intake manifold.
  5. Disconnect and remove the fuel supply and return lines from the fuel rail assembly.
  6. Remove the fuel rail and injectors.
  7. Loosen the accessory drive belts.
  8. Remove the power steering pump.
  9. Disconnect the exhaust pipe from the manifold and discard the seal.
  10. Remove the intake and exhaust manifold attaching nuts and bolts.
  11. Remove the manifold assembly and gasket.

Installation of Exhaust and Intake Manifold

  1. Clean the gasket mating surfaces thoroughly. Install a new gasket over the alignment dowels and position the exhaust manifold to the cylinder head. Install bolt No. 3 finger-tight.
  2. Install the intake manifold and the remaining bolts and washers.
  3. On 1987-90 models, tighten bolts, in sequence, to the following torque specifications:
    1. Bolt 1-30 ft. lbs. (40.5 Nm)
    2. Bolts 2-11-23 ft. lbs. (31 Nm)
    3. Bolts 12 and 13-30 ft. lbs. (40.5 Nm)
    4. See Figure 1
  4. On 1991-98 models, tighten bolts, in sequence, to the following torque specifications:
    1. Bolts 1-5-23 ft. lbs. (31 Nm)
    2. Bolts 6 and 7-17 ft. lbs. (23 Nm)
    3. Bolts 8-11-23 ft. lbs. (31 Nm)
    4. See Figure 2
  5. Install the fuel rail and injectors.
  6. Install the power steering pump and tension the accessory belt to specification.
  7. Using new O-rings, install the fuel supply and return lines.
  8. Connect all electrical connectors, vacuum connectors, throttle cable, cruise control cable and transmission lines pressure cable.
  9. Install the air cleaner assembly.
  10. Using a new seal, connect the exhaust pipe to the manifold and tighten the bolts to 23 ft. lbs. (31 Nm).
  11. Connect the negative battery cable.
  12. Start the engine and check for leaks.
Fig. 1: Torque sequence for 1987-90 models

Fig. 1: Torque sequence for 1987-1990 models

Fig. 2: Torque sequence for 1991-98 models

Fig. 2: Torque sequence for 1991-1998 models