REMOVAL & INSTALLATION
| WARNING | Deactivate air bag system before performing any service operation. See appropriate AIR BAG RESTRAINT SYSTEMS article. Do not apply electrical power to any component on steering column without first deactivating air bag system. Air bag may deploy. |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Removal & Installation (3.5L)
Disconnect negative battery cable. Raise and support vehicle. Remove lower air deflector. Remove flywheel cover. Disconnect starter solenoid wiring. Remove starter motor retaining bolts. Remove starter. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
Removal (4.0L)
- Disconnect negative battery cable. Remove intake manifold cover. Disconnect ignition coil module connectors. Disconnect PCV hoses. Disconnect vacuum hoses from fuel regulator and AIR solenoid. Relieve fuel pressure. Disconnect fuel inlet and fuel return quick connect fittings at fuel rail. Remove fuel rail retaining nut at rear engine lift bracket.
- Remove 2 push nuts and remove engine coolant heater wire (if equipped) and position aside. Carefully remove surge tank pipe from fuel rail studs and position aside. Disconnect the 8 fuel injector electrical connectors. Remove 4 stud bolts and remove fuel rail and injector assembly from intake manifold.
- Loosen air duct clamp from plenum at rear of intake manifold. Remove the 10 intake manifold retaining bolts. Remove intake manifold. Disconnect electrical connectors from starter solenoid. Remove the 2 retaining bolts and remove starter motor assembly.
Installation
- Connect electrical connectors to starter solenoid and tighten nuts to specification. Install starter motor assembly and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-128014-S38796062622001110100000).
- Lightly grease inside edge of rubber air duct. Clean mating surfaces of intake manifold and cylinder heads. Install NEW gaskets to intake manifold. Ensure PCV hose is securely attached to fitting on front of intake manifold.
- Position intake manifold to install rear air plenum into rubber air duct. Lower intake manifold onto cylinder heads. Install 10 intake manifold retaining bolts and tighten to specification, in sequence. (Scheme 2) Ensure air plenum is fully attached to rubber air duct at rear of manifold and tighten clamp.
- Lubricate intake manifold fuel injector bores with clean engine oil. Install fuel rail and injector assembly to intake manifold. Install fuel rail retaining stud bolts and tighten to specification. See «TORQUE SPECIFICATION»(ref-128014-S38796062622001110100000). To complete installation, reverse removal procedure.
Scheme 2
