2012 Jeep Wrangler JK Factory Service Manual 09 - Engine, 2.8L Diesel

MANIFOLD, Intake

REMOVAL

REMOVAL

  1. Disconnect the negative battery cable.

    2.  
  2. Remove the EGR cooler (Refer to 07 - Cooling/Engine/COOLER, EGR - Removal) .

    3.  
  3. Remove the coolant recovery bottle (Refer to 07 - Cooling/Engine/BOTTLE, Coolant Recovery - Removal) .

    4.  
  4. Disconnect the tuning valve harness connector (1).

    5.  
  5. Disconnect the fuel injector return line (1) from intake manifold (3).

    6.  
  6. Disconnect the vacuum line (2) from vacuum solenoid and intake manifold (3).

    7.  
  7. Disconnect the vacuum solenoid harness connector (1).

    8.  
  8. Remove the fuel rail (2) (Refer to 14 - Fuel System/Fuel Delivery/RAIL, Fuel - Removal) .

    9.  
  9. Remove the glow plug wire harness clip (1) from generator mounting bracket.

    10.  
  10. Disconnect glow plug (3) and remove the wire harness (2).

    11.  
  11. Remove nuts (7) and the intake manifold (4).

    12.  
  12. Remove the intake manifold gasket.

    13.  

INSTALLATION

INSTALLATION

  1. Clean and inspect the gasket surface of the intake manifold and the cylinder head.

    2.  
  2. Install the intake manifold gasket (1) and water jacket gasket (2).

    NOTE:

    The thermostat housing will be installed after the fuel rail is installed.


    3.  
  3. Install the intake manifold (4) and tighten nuts finger tight.

    4.  
  4. Connect glow plug (3) and remove the wire harness (2).

    5.  
  5. Install glow plug wire harness clip (1) to the generator mounting bracket.

    6.  
  6. Install the fuel rail (2) (Refer to 14 - Fuel System/Fuel Delivery/RAIL, Fuel - Installation) .



    7.  
  7. Using the tightening sequence shown, tighten nuts 5, 1, 2, 6 to 5 N·m (44 in. lbs.).

    8.  
  8. Using the tightening sequence shown, tighten nuts 1 through 9 to 12 N·m (106 in. lbs.).

    9.  
  9. Connect the vacuum solenoid harness connector (1).

    10.  
  10. Connect the vacuum line (2) to the vacuum solenoid and intake manifold (3)

    11.  
  11. Connect the fuel injector return line (1) to the intake manifold (3).

    12.  
  12. Connect the tuning valve harness connector (1).

    13.  
  13. Install the coolant recovery bottle (Refer to 07 - Cooling/Engine/BOTTLE, Coolant Recovery - Installation) .

    14.  
  14. Install the EGR cooler (Refer to 07 - Cooling/Engine/COOLER, EGR - Installation) .

    15.  
  15. Connect the negative battery cable.

    16.  
  16. Start the engine and check for leaks.

    17.