Liberty 2WD L4-2.4L VIN 1 (2005)
Intake Manifold: Service and Repair
Upper Intake Manifold
REMOVAL - UPPER
1. Disconnect negative cable from battery.
2. Disconnect connector from inlet air temperature sensor.
3. Disconnect air intake tube at throttle body and remove upper air cleaner housing.
4. Disconnect connector from throttle position sensor (TPS).
5. Disconnect connector from idle air control (IAC) motor.
6. Disconnect connector from MAP sensor.
7. Remove vacuum lines for purge solenoid and PCV valve at intake manifold.
8. Remove vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold
fittings.
9. Disconnect throttle, speed control (if equipped), and transaxle control (if equipped) and cables from throttle lever and bracket.
10. Perform fuel system pressure release procedure before attempting any repairs.
11. Disconnect fuel line.
12. Disconnect coolant temperature sensor/fuel injector wire harness connector.
13. Disconnect fuel injector harness.
14. Remove intake manifold to cylinder head fasteners.
15. Remove the manifold from engine.
CAUTION: Cover intake manifold openings to prevent foreign material from entering engine.
16. Inspect the manifold.
INSPECTION
1. Check manifold surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 inch per foot) of manifold
length.
2. Inspect manifold for cracks or distortion. Replace manifold if necessary.
INSTALLATION - UPPER
1. Clean manifold sealing surfaces.
2. Apply a 1.5 mm (0.060 inch) bead Mopar Gasket Maker to the perimeter of the lower intake manifold runner openings.
3. Install upper intake manifold and tighten fasteners to 28 Nm (250 inch lbs.) in sequence shown in (Fig. 98). Repeat this procedures until all
fasteners are at specified torque.
4. Install engine oil dipstick.
5. Install upper bolt in intake manifold to front support bracket.
6. Install EGR tube.
7. Install throttle cables in bracket.
8. Connect throttle, speed control, (if equipped), cables to throttle lever.
9. Connect vacuum lines for power brake booster, LDP, EGR transducer, and speed control vacuum reservoir (if equipped) at upper intake manifold
fittings.
10. Connect vacuum lines for purge solenoid and PCV valve.
11. Connect electrical connectors for MAP sensor, throttle position sensor (TPS), and idle air control (IAC) motor.
12. Install air cleaner upper housing and air intake tube to throttle body.
13. Connect inlet air temperature sensor connector.
14. Connect negative cable to battery.