Jeep 1996 Grand Cherokee Service Manual - page 1029
INSTALLATION
(1) If the tailpipe hanger assembly was removed,
install the hanger to the frame. Tighten the bolts to
22 N·m (192 in. lbs.) torque.
(2) Position the tailpipe and muffler onto the
tailpipe hanger (Fig. 10).
(3) Install the muffler onto the catalytic converter.
Make sure that the tailpipe has sufficient clearance
from the floor pan. Install Torca clamp and tighten
the nuts to 75 N·m (55 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
INTAKE AND EXHAUST MANIFOLD—4.0L ENGINE
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD
MUST
BE
REMOVED
AND
INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Disconnect the negative cable from the battery.
(2) Remove air cleaner inlet hose from throttle
plate assembly.
(3) Remove the air cleaner assembly.
(4) Remove the throttle cable, vehicle speed control
cable (if equipped) and the transmission line pres-
sure cable.
(5) Disconnect all electrical connectors on the
intake manifold.
(6) Disconnect and remove the fuel system supply
and return lines from the fuel rail assembly (refer to
Group 14, Fuel System).
(7) Loosen the accessory drive belt (refer to Group
7, Cooling System). Loosen the tensioner.
(8) Remove the power steering pump and bracket
from the intake manifold and set aside.
(9) Remove the fuel rail and injectors (refer to
Group 14, Fuel System).
(10) Raise the vehicle.
(11) Disconnect the exhaust pipe from the engine
exhaust manifold. Discard the seal.
(12) Lower the vehicle.
(13) Remove
the
intake
manifold
and
engine
exhaust manifold.
INSTALLATION
If the manifold is being replaced, ensure all the fit-
ting, etc. are transferred to the replacement mani-
fold.
(1) Install a new engine exhaust/intake manifold
gasket over the alignment dowels on the cylinder
head.
(2) Position the engine exhaust manifold to the
cylinder head. Install fastener Number 3 and finger
tighten at this time (Fig. 11).
(3) Install intake manifold on the cylinder head
dowels.
(4) Install washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fig. 11).
(5) Install washer and fastener Numbers 6 and 7
(Fig. 11).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 11).
• Fastener Numbers 1 through 5—Tighten to 33
N·m (24 ft. lbs.) torque.
• Fastener Numbers 6 and 7—Tighten to 31 N·m
(23 ft. lbs.) torque.
• Fastener Numbers 8 through 11—Tighten to 33
N·m (24 ft. lbs.) torque.
(7) Install the fuel rail and injectors (refer to
Group 14, Fuel System).
(8) Install the power steering pump and bracket to
the intake manifold. Tighten the belt to specification
(refer to Group 7, Cooling System for the proper pro-
cedures).
Fig. 10 Tailpipe Hanger
Fig. 11 Engine Exhaust/Intake Manifold
11 - 6
EXHAUST SYSTEM AND INTAKE MANIFOLD
ZJ
REMOVAL AND INSTALLATION (Continued)