ENGINE PERFORMANCE DIAGNOSTIC TABLE
| CONDITION | POSSIBLE CAUSE | CORRECTION |
|---|---|---|
| ENGINE WILL NOT START | 1. Weak battery | 1. Charge or replace as necessary. Refer to BATTERY, DIAGNOSIS AND TESTING . |
| 2. Corroded or loose battery connections. | 2. Clean and tighten battery connections. Refer to CLEANING . | |
| 3. Faulty engine starting system. | 3. Diagnose engine starting system. Refer to DIAGNOSIS AND TESTING . | |
| 4. Faulty coil or control unit. | 4. Replace ignition coil. Refer to COIL, IGNITION, REMOVAL . | |
| 5. Incorrect spark plug gap. | 5. Correct as necessary. | |
| 6. Incorrect cam timing. | 6. Verify cam timing. Refer to VALVE TIMING - STANDARD PROCEDURE . | |
| 7. Dirt or water in fuel system. | 7. Clean fuel system. | |
| 8. Faulty fuel pump or wiring. | 8. Repair or replace as necessary. | |
| 9. Faulty Camshaft Position (CMP) sensor. | 9. Replace sensor. Refer to SENSOR, CAMSHAFT POSITION, REMOVAL . | |
| 10. Faulty Crankshaft Position (CKP) sensor. | 10. Replace sensor. Refer to SENSOR, CRANKSHAFT POSITION, REMOVAL . | |
| 11. Insufficient quantity of engine oil in the Variable Valve Actuation Assembly due to: Long term storage Engine not started within the last 30 days Replaced Variable Valve Actuation Assembly (MultiAir module) | 11. Operate the starter to fill the Variable Valve Actuation Assembly with oil and enable its operation. CAUTION: Do not exceed 20 seconds of starter operation and allow 60 seconds cool-down between cycles. | |
| ENGINE STALLS OR ROUGH IDLE | 1. Vacuum leak. | 1. Inspect intake manifold and vacuum hoses, repair or replace as necessary. |
| 2. Faulty Crankshaft Position (CKP) sensor. | 2. Replace sensor. Refer to SENSOR, CRANKSHAFT POSITION, REMOVAL . | |
| 3. Faulty ignition coil. | 3. Replace ignition coil. Refer to COIL, IGNITION, REMOVAL . | |
| 4. Incorrect cam timing. | 4. Verify cam timing. Refer to VALVE TIMING - STANDARD PROCEDURE . | |
| ENGINE LOSS OF POWER | 1. Dirty or incorrectly gapped spark plugs. | 1. Correct as necessary. Refer to SPARK PLUG, REMOVAL . |
| 2. Dirt or water in fuel system. | 2. Clean fuel system. | |
| 3. Faulty fuel pump. | 3. Replace fuel pump. Refer to MODULE, FUEL PUMP, REMOVAL . | |
| 4. Leaking cylinder head gasket. | 4. Replace cylinder head gasket. Refer to CYLINDER HEAD, REMOVAL . | |
| 5. Low compression. | 5. Determine the cause and repair as necessary. Refer to CYLINDER COMPRESSION PRESSURE LEAKAGE . | |
| 6. Burned, warped or pitted valves. | 6. Replace as necessary. Refer to VALVES, INTAKE AND EXHAUST, REMOVAL . | |
| 7. Plugged or restricted exhaust system. | 7. Inspect and replace as necessary. | |
| 8. Faulty ignition coil. | 8. Replace ignition coil. Refer to COIL, IGNITION, REMOVAL . | |
| 9. Incorrect cam timing. | 9. Verify cam timing. Refer to VALVE TIMING - STANDARD PROCEDURE . | |
| ENGINE MISSES ON ACCELERATION | 1. Dirty or incorrectly gapped spark plugs. | 1. Correct as necessary. Refer to SPARK PLUG, REMOVAL . |
| 2. Dirt in fuel system. | 2. Clean fuel system. | |
| 3. Burned, warped or pitted valves. | 3. Replace as necessary. Refer to VALVES, INTAKE AND EXHAUST, REMOVAL . | |
| 4. Faulty ignition coil. | 4. Replace ignition coil. Refer to COIL, IGNITION, REMOVAL . | |
| ENGINE MISSES AT HIGH SPEED | 1. Dirty or incorrectly gapped spark plugs. | 1. Correct as necessary. Refer to SPARK PLUG, REMOVAL . |
| 4. Faulty ignition coil. | 2. Replace ignition coil. Refer to COIL, IGNITION, REMOVAL . | |
| 3. Dirt or water in fuel system. | 3. Clean fuel system. |
ENGINE MECHANICAL DIAGNOSTIC TABLE
| CONDITION | POSSIBLE CAUSES | CORRECTIONS |
|---|---|---|
| NOISY VALVES | 1. High or low oil level in crankcase. | 1. Refer to OIL - STANDARD PROCEDURE . |
| 2. Thin or diluted oil. | 2. Change oil and filter. | |
| 3. Low oil pressure. | 3. Check oil pump, if Ok, check rod and main bearings for excessive wear. | |
| 4. Dirt in lash adjusters. | 4. Replace as necessary. | |
| 5. Worn rocker arms. | 5. Replace as necessary. | |
| 6. Worn lash adjusters | 6. Replace as necessary. | |
| 7. Worn valve guides. | 7. Inspect the valve guides for wear, cracks or looseness. If either condition exists, replace the cylinder head. Refer to CYLINDER HEAD, REMOVAL . | |
| 8. Excessive runout of valve seats on valve faces. | 8. Refer to VALVES, INTAKE AND EXHAUST - STANDARD PROCEDURE . | |
| CONNECTING ROD NOISE | 1. Insufficient oil supply. | 1. Refer to OIL - STANDARD PROCEDURE . |
| 2. Low oil pressure. | 2. Check oil pump, if OK, check rod and main bearings for excessive wear. | |
| 3. Thin or diluted oil. | 3. Change oil and filter. | |
| 4. Excessive bearing clearance. | 4. Replace as necessary. | |
| 5. Connecting rod journal out-of-round. | 5. Service or replace crankshaft. | |
| 6. Misaligned connecting rods. | 6. Replace bent connecting rods. | |
| MAIN BEARING NOISE | 1. Insufficient oil supply. | 1. Refer to OIL - STANDARD PROCEDURE . |
| 2. Low oil pressure. | 2. Check oil pump, if OK, check rod and main bearings for excessive wear. | |
| 3. Thin or diluted oil. | 3. Change oil and filter. | |
| 4. Excessive bearing clearance. | 4. Replace as necessary. | |
| 5. Excessive end play. | 5. Check thrust washers for wear. | |
| 6. Crankshaft journal out-of round. | 6. Service or replace crankshaft. | |
| 7. Loose flywheel or torque converter. | 7. Tighten to correct torque |
OIL CONSUMPTION TEST AND DIAGNOSIS
The following diagnostic procedures are used to determine the source of excessive internal oil Consumption, these procedures and tests apply to vehicles with 50, 000 miles or less.
Note. Engine oil consumption may be greater than normal during engine break-in. Repairs should be delayed until vehicle has been driven at least 7, 500 miles.
Severe service (high ambient temperature, short trips, heavy loading, trailer towing, taxi, off-road, or law enforcement use) may result in greater oil consumption than normal.
Sustained high speed driving and high engine RPM operation may result in increased oil consumption.
Failure to comply with the recommended oil type and viscosity rating, as outlined in the Owner's Manual, may impact oil economy as well as fuel economy.
Oil consumption may increase with vehicle age and mileage due to normal engine wear.
Note. Because a few drops of external oil leakage per mile can quickly account for the loss of one quart of oil in a few hundred miles, ensure no external engine oil leaks are present.
- Oil leakage is not the same as oil consumption and all external leakage must be eliminated before any action can be taken to verify and/or correct oil consumption complaints.
- Verify that the engine has the correct oil level dipstick and dipstick tube installed.
- Verify that the engine is not being run in an overfilled condition. Check the oil level 15 minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the level be above MAX or the FULL mark on the dipstick.
OIL CONSUMPTION TEST
- Check the oil level at least 15 minutes after a hot shutdown.
- If the oil level is low, top off with the proper viscosity and API service level engine oil. Add one bottle of MOPAR® 4-In-1 Leak Detection Dye into the engine oil.
- Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap.
- Record the vehicle mileage.
- Instruct the customer to drive the vehicle as usual.
- Ask the customer to return to the servicing dealer after accumulating 500 miles, Check the oil level at least 15 minutes after a hot shutdown. If the oil level is half way between the "FULL" and "ADD" mark continue with the next step.
- Using a black light, re-check for any external engine oil leaks, repair as necessary, if no external engine oil leaks are present, continue with oil consumption diagnosis.
OIL CONSUMPTION DIAGNOSIS
- Check the positive crankcase ventilation (PCV) system. Make sure the system is not restricted and the PCV valve has the correct part number and correct vacuum source (18-20 in. Hg at idle below 3000 ft. above sea level is considered normal).
- Perform a cylinder compression test and cylinder leak down test using the standard leak down gauge following manufacturers suggested best practices. NOTE: Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault.
- If one or more cylinders have more than 15% leak down further engine tear down and inspection will be required.
ENGINE LUBRICATION DIAGNOSTIC TABLE
| CONDITION | POSSIBLE CAUSES | CORRECTION |
|---|---|---|
| OIL LEAKS | 1. Gaskets and O-rings. Misaligned or damaged. | 1. Replace as necessary. |
| (a) Loose fasteners, broken or porous metal parts. | (a) Tighten fasteners, Repair or replace metal parts. | |
| 2. Crankshaft rear oil seal. | 2. Replace rear crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, REAR, REMOVAL . | |
| 3. Crankshaft rear oil seal surface. Scratched, nicked or grooved. | 3. Polish or replace crankshaft. | |
| 4. Oil pan flange cracked. | 4. Replace oil pan. Refer to PAN, OIL, REMOVAL . | |
| 5. Crankshaft front oil seal. | 5. Replace front crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, FRONT, REMOVAL . | |
| 6. Crankshaft front oil seal surface. Scratched, nicked or grooved. | 6. Polish or replace crankshaft. | |
| OIL PRESSURE DROP | 1. Low oil level. | 1. Check and correct oil level. |
| 2. Faulty oil pressure switch. | 2. Replace switch. Refer to SWITCH, OIL PRESSURE, REMOVAL . | |
| 3. Low oil pressure. | 3. Check main bearing clearance. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE . 3. Check rod bearing clearance. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE . | |
| 4. Clogged oil filter. | 4. Replace oil filter. Refer to FILTER, ENGINE OIL, REMOVAL . | |
| 5. Worn oil pump. | 5. Replace oil pump. Refer to PUMP, ENGINE OIL, REMOVAL . | |
| 6. Thin or diluted oil. | 6. Change oil and filter. Refer to OIL - STANDARD PROCEDURE . | |
| 7. Excessive bearing clearance. | 7. Replace crankshaft bearings. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE . 7. Replace rod bearings. Refer to BEARING(S), CONNECTING ROD - STANDARD PROCEDURE . | |
| 8. Oil pump relief valve stuck. | 8. Replace oil pump. Refer to PUMP, ENGINE OIL, REMOVAL . | |
| 9. Oil pump pick-up tube loose, damaged or clogged. | 9. Replace oil pump pick-up. Refer to PICK-UP, OIL PUMP, REMOVAL . | |
| OIL PUMPING AT RINGS; SPARK PLUGS FOULING | 1. Worn or damaged rings. | 1. Hone cylinder bores and replace rings. Refer to RING(S), PISTON - STANDARD PROCEDURE . |
| 2. Carbon in oil ring slots. | 2. Replace rings. Refer to ROD, PISTON AND CONNECTING, REMOVAL . | |
| 3. Worn valve guides. | 3. Replace cylinder heads. Refer to CYLINDER HEAD, REMOVAL . | |
| 4. Leaking valve guide seals. | 4. Replace valve guide seals. Refer to SEAL(S), VALVE GUIDE, REMOVAL . |
Scheme 6
Due to the high amounts of failures caused by dust, dirt, moisture and other foreign debris being introduced to the engine during service. Covers or caps are needed to reduce the possible damage that can be caused or created.
Scheme 7
Covers over openings will reduce any possibilities for foreign materials to enter the engine systems. Using miller tool (special tool #10368, Set, Universal Protective Cap), Select the appropriated cover needed to the procedure.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test. Refer to CYLINDER COMPRESSION PRESSURE LEAKAGE . An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50 - 70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
| WARNING | USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRESSURE CAP REMOVED. |
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.
If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.
Scheme 8
| WARNING | WITH THE COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT THE PRESSURE TO EXCEED 138 kPa (20 psi). |
Install Cooling System Tester (special tool #7700-A, Tester, Cooling System) or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
Scheme 9
Combustion leaks into the cooling system can also be checked by using (special tool #C-3685-A, Bloc-Chek Kit) or equivalent. Perform test following the procedures supplied with the tool kit.
INSPECTION
- Verify that the valve tappets move freely in theirs bores and that they have been rotating.
- Inspect camshaft bearing journals for scoring.
- Inspect the following components and verify that they are within specification. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) . Camshafts Valve Tappets
DIAGNOSIS AND TESTING - LASH ADJUSTER (TAPPET) NOISE
Proper noise diagnosis is essential in locating the source of an NVH complaint. Locating a lash adjuster (tappet) type noise can sometimes be difficult. As a result, an initial misdiagnosis may occur.
Refer to the following chart for possible causes and correction of a lash adjuster (tappet) type noise
| POSSIBLE CAUSES | CORRECTION |
|---|---|
| 1. Engine oil level-too high or too low. This may allow aerated oil to enter the adjusters and cause them to be spongy. | 1. Check and correct the engine oil level. |
| 2. Insufficient running time after rebuilding a cylinder head. | 2. Low speed running of up to 1 hour may be required to fully evacuate trapped air from the valve train system. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. |
| 3. Air trapped in the lash adjuster (after 1 hour of run time). | 3. See below |
| (a) Check lash adjusters for sponginess while installed in the cylinder head. Depress the lash adjuster. Normal adjusters should feel very firm. Very spongy adjusters can be bottomed out easily. | |
| (b) If the lash adjuster(s) are still spongy, replace the lash adjuster(s). Refer to LIFTER(S), HYDRAULIC, REMOVAL . | |
| 4. Low oil pressure. | 4. See below |
| (a) Check and correct the engine oil level. | |
| (b) Check the engine oil pressure. Refer to LUBRICATION - DIAGNOSIS AND TESTING . | |
| (c) Check for excessive main bearing clearance and correct. Refer to BEARING(S), CRANKSHAFT, MAIN - STANDARD PROCEDURE . | |
| (d) Check for a worn oil pump. | |
| 5. Oil passage to the cylinder head(s) plugged with debris. | 5. Check cylinder head oil passages for blockage. Clean or replace as necessary. |
| 6. Worn valve guide(s). | 6. Measure valve stem-to-guide clearance. Refer to VALVES, INTAKE AND EXHAUST - INSPECTION . |
| 7. Air ingested into oil due to broken or cracked oil pump pickup tube. | 7. Inspect pickup tube and replace as necessary. Refer to PICK-UP, OIL PUMP, REMOVAL . |
| 8. Collapsed lash adjuster due to debris ingestion. | 8. Clean debris from engine and replace lash adjuster(s). Refer to LIFTER(S), HYDRAULIC, REMOVAL . |
LASH ADJUSTER (TAPPET) NOISE CHART
Inspect the valve rocker arm for wear or damage. Replace as necessary.
AIR LEAK DETECTION TEST METHOD
- Disconnect the fresh air make-up hose from the oil filler neck. Cap or plug the make-up air hose nipple.
- Remove the PCV hose from the PCV valve. Cap or plug the PCV valve nipple.
- Attach an air hose with a pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kPa (3 PSI) of test pressure.
- Gradually increase air pressure from 7 kPa (1 psi) to 17 kPa (2.5 psi) maximum while applying soapy water at the suspected leak source. Adjust the regulator to a suitable test pressure within this range that provides the best bubble generation which will pinpoint the leak source. If the oil leak is detected and identified, repair per Service Information procedures.
- If the leakage occurs at the rear crankshaft oil seal area, follow the procedures for rear seal area leaks. Refer to «LUBRICATION - DIAGNOSIS AND TESTING»(ref-646215-S24289765042014072800000) .
- If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and make-up air hoses.
- Clean the oil off of the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
Scheme 10
Note. The oil pressure switch has a lock patch on the threads and if removed can not be reinstalled.
Scheme 11
- Disconnect and isolate the negative battery cable.
- Remove the oil pressure switch (2) from the oil pump. Refer to «SWITCH, OIL PRESSURE, REMOVAL»(ref-646215-S09171637762014072800000) .
- Install the Oil Pressure Gauge Adapter (special tool #10282, Adapter, Engine Oil Pressure) (2) to the oil pressure port. Tighten to 32 N.m (24 ft. lbs.).
- Install the Oil Pressure Gauge (special tool #C-3292A, Gauge, Pressure) (1) to the adapter (2). Tighten to 20 N.m (177 in. lbs.).
- Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
- Start and idle the engine. If oil pressure is 0 at idle, shut off the engine and consult the Engine Lubrication and Diagnostic Table. Refer to «ENGINE - DIAGNOSIS AND TESTING»(ref-646215-S39624165502014072800000) .
- Run the engine until it reaches normal operating temperature.
- Verify that the engine has acceptable oil pressure. Refer to «ENGINE SPECIFICATIONS»(ref-646215-S03916579012014072800000) .
Scheme 12
The oil cooler is attached to the side of the oil filter housing which is located on the left side of the cylinder block. The oil cooler is a plate style coolant-to-oil heat exchanger.
Scheme 13
Oil flows from the oil pump, through the oil filter housing and into the oil cooler (2). After the oil is cooled it travels back to the oil filter housing (4) where it is filtered and returned to the oil pump housing and the main engine oil gallery.
Engine coolant from the thermostat housing flows through the oil filter housing into the oil cooler (1). The coolant exits the oil cooler (3) and is returned to the water pump inlet.
Scheme 14
Note. The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, replace the oil cooler.
Scheme 15
Scheme 16
- Disconnect and isolate the negative battery cable.
- Drain the engine oil. Refer to «OIL - STANDARD PROCEDURE»(ref-646215-S41491917222014072800000) .
- Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
- Remove four bolts (3) and the lower oil cooler housing heat shield (2).
- Remove six bolts (2).
- Remove the oil cooler (1).
- Remove and discard the oil cooler seal (1).
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
| WARNING | Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or the fan. Do not wear loose clothing. |
- Start the engine.
- Spray a small stream of water (spray bottle) at the suspected leak area.
- If engine RPM'S change, the area of the suspected leak has been found.
- Repair as required.
Scheme 17
Scheme 18
Scheme 19
Scheme 20
Scheme 21
Scheme 22
Scheme 23
Scheme 24
Scheme 25
Scheme 26
Scheme 27
- Perform the fuel pressure release procedure. Refer to «FUEL DELIVERY, GAS , STANDARD PROCEDURE»(ref-646230-S42658421212014072800000) .
- Remove the engine cover assembly.
- Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
- Disconnect the PCV hose (1) from the intake manifold.
- Disconnect the vent hose (3) from the cylinder head cover.
- Remove three bolts (2) and remove the oil separator housing (4) from the cylinder head cover. CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.
- Disconnect and remove the battery. Refer to «BATTERY, REMOVAL»(ref-646227-S35480669362014072800000) .
- Unlock and disconnect the Powertrain Control Module (PCM) harness connectors (1 and 2).
- Disengage two engine wire harness retainers (4) from the battery tray (3).
- Disengage the engine wire harness connector (2) from the battery tray (3) and reposition the wire harness.
- Remove the nut (5) and two bolts (1) securing battery tray.
- Remove the battery tray with the PCM (2) attached.
- Unlock and disconnect the harness connector (1) from the Electronic Throttle Control (ETC).
- Disconnect the EVAP purge hose (4) from the retaining clip (3).
- Loosen the clamp (2) securing the charge air cooler outlet hose to throttle body.
- Remove two bolts (2), one nut (3) and reposition the oil separator housing bracket (1).
- Disengage the EVAP purge hose (4) from the retaining clip (2) and remove the hose from the charge air cooler outlet hose (5).
- Disconnect the boost pressure sensor wire harness connector (1).
- Remove the bolts (3) from the charge air cooler outlet hose (5).
- Disconnect the charge air cooler outlet hose (5) from the charge air outlet manifold and remove the hose from the vehicle.
- Open hose retainer (2) and disconnect the fuel vapor purge hose.
- Disconnect the fuel line (1) from the fuel rail. Refer to «FITTING, QUICK CONNECT, STANDARD PROCEDURE»(ref-646230-S25407444222014072800000) . CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.
- Disconnect the vacuum line from the vacuum pump (1).
- Unlock and disconnect the IAT/MAP sensor harness connector (1).
- Unlock and disconnect the fuel injector wire harness connector (1).
- Disengage and reposition the purge flow control solenoid (1) from the bracket (4).
- Remove two nuts (1), bolt (7), and the bracket (2).
- Disengage the retainers (5) from the support bracket (4).
- Remove the nut (3), bolt (6), and the support bracket (4).
- Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
- Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
- Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
- Remove four bolts (1) and the tunnel support brace (2).
- Remove both front wheels and tires. Refer to «REMOVAL»(ref-646212-S02251014372014072800000) .
- Remove two bolts (4) and the right vertical brace (5).
- Remove two screws (2) from the front wheelhouse splash shield.
- Remove three screws (1) and the frame splash shield (3).
- Remove the accessory drive belt (4). Refer to «BELT, SERPENTINE, REMOVAL»(ref-646235-S33730159442014072800000) .
- Lower the vehicle.
- Remove the A/C compressor (1). Refer to «COMPRESSOR, A/C, REMOVAL»(ref-646220-S17088941942014072800000) .
- Disconnect the heater core outlet hose (3) and inlet hose (4) from the heater core.
- Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
- Open the two wire harness retainers (1) and reposition the wire harness.
- Lower the vehicle.
- Remove the bolt (2) securing the hose retainer (1) to the intake manifold.
- Remove the seven intake manifold flange bolts (1) and remove the intake manifold from vehicle.
- Remove and discard the four intake manifold seals (1).
- Cover the open intake ports to prevent debris from entering the engine.
- If required, remove the following components from the intake manifold: Throttle body. Refer to «THROTTLE BODY, REMOVAL»(ref-646230-S20794439832014072800000) . Fuel rail. Refer to «RAIL, FUEL, REMOVAL»(ref-646230-S37419035952014072800000) . Fuel injector(s). Refer to «INJECTOR(S), FUEL, REMOVAL»(ref-646230-S05006668252014072800000) . Evaporative emissions purge valve. IAT/MAP sensor. Refer to «SENSOR, MANIFOLD AIR PRESSURE (MAP), REMOVAL»(ref-646230-S40859222602014072800000) .
Check the intake manifold for
- Damage and cracks
- Gasket surface damage or warpage
- Damaged fuel injector ports
If the intake manifold exhibits any damaged or warped conditions, replace the manifold.