Attention! Wait until the engine has completely cooled down before starting this procedure.
Removing
1. Relieve pressure in the fuel system (see chapter 4). Disconnect the ground wire from the batteries (see paragraph 1 of chapter 5).
2. Remove the air inlet (see chapter 4).
3. Remove the fuel rail and injectors as a single assembly (see chapter 4). Remove throttle body (see chapter 4).
4. Tag and disconnect the positive crankcase ventilation hoses and vacuum hoses connected to the intake manifold (pic. 8.4). Raise the vehicle and place secure supports under it.
Pic. 8.4. Label vacuum hose (And) (A) and unplug it (their) from the intake manifold, remove the retainer (s) wiring harness (IN)
Attention. If the vehicle is equipped with electronically controlled air suspension, turn off the suspension height catch switch.
Note. If you work with an all-wheel drive option (4WD), before lifting the vehicle, loosen the right axle/hub nut (see chapter 8) and right front wheel nuts.
All-wheel drive options (4WD)
5. Drain the transmission oil from the transfer case (see chapter 1).
6. Remove the right half shaft (see chapter 8).
7. Separate the support from the transfer case. Remove the transfer case support tie.
All models
8. Working under the vehicle, remove the lower manifold mounting bolts (pic. 8.8).
Pic. 8.8. The location of the lower bolts of the intake manifold
9. Working from above, remove the nuts and remove the manifold mounting bolts. Remove the manifold, gasket and manifold support pad from the engine (pic. 8.9).
Pic. 8.9. The location of the upper elements of the intake manifold
Installation
10. Clean the mating surfaces of the intake manifold and cylinder head with lacquer thinner or acetone. If the gasket shows leakage grafting, check the flatness of the manifold mating surface using a hard ruler and a set of feeler gauges. If the mating surface is deformed, the manifold must be replaced.
11. Insert a new gasket into the groove on the manifold (pic. 8.11). Install the manifold and gasket, following the studs on the cylinder head.
Pic. 8.11. Insert the gasket into the groove on the intake manifold
12. Evenly, in three or four stages, tighten the nuts / bolts securing the manifolds to the cylinder head to the prescribed torque specified in Specifications at the beginning of this chapter. Start with the top bolts to avoid deforming the manifold.
13. Install the remaining elements, working in the reverse order of removal. Check coolant level and top up if necessary (see chapter 1).
14. On all-wheel drive models, refuel the transfer case (see chapter 1).
15. Before starting the engine, check the smooth operation of the accelerator cable (if available).
16. Start the engine and check for coolant leaks and vacuum.
17. Road test the vehicle and check the reliability of all auxiliary systems and assemblies, including the cruise control system (if available).