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Home › Jeep › 2021 › Compass Trailhawk › Repair and Diagnosis › Engine Mechanical › Mechanical › 2.4L Engine (Service Information) › Manifolds › Manifold, Intake › Removal And Installation › Installation

Removal And Installation: Installation

  1. If removed, install the fuel injectors and fuel rail. Refer to INJECTOR(S), FUEL, REMOVAL AND INSTALLATION .
  2. Clean all gasket surfaces.
    GC0170043Courtesy of CHRYSLER GROUP, LLC
  3. The manifold gaskets (1) can be reused if not damaged.
  4. If removed, install the foam pad over the coolant pump inlet tube.
    GC0155603Courtesy of CHRYSLER GROUP, LLC
  5. Install the intake manifold to the cylinder head and install the five fasteners (1, 2).
    Fig 1: Intake Manifold Fasteners Tightening Sequence
    GC0188494Courtesy of CHRYSLER GROUP, LLC
  6. Using the sequence shown in illustration, tighten the fasteners to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0155794Courtesy of CHRYSLER GROUP, LLC
  7. Install the intake manifold silencer cover and tighten the four screws (1) to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0169941Courtesy of CHRYSLER GROUP, LLC
  8. Position the wire harness tray onto the cylinder head cover and install the three wire harness tray retainers (2).
  9. Connect and lock the four fuel injector wire harness connectors (4).
  10. Connect and lock the four VVAA solenoid wire harness connectors (3).
  11. Install the purge solenoid (1) to its fuel rail mount.
    GC0169966Courtesy of CHRYSLER GROUP, LLC
  12. Engage the two wire harness retainers (3) to the intake manifold.
  13. Connect the purge line (4), PVC hose (2) and brake booster hose (if equipped) to the intake manifold.
    GC0163080Courtesy of CHRYSLER GROUP, LLC
  14. Remove the tape or plugs from the opened refrigerant line fittings and ports.
  15. Lubricate and install a new O-ring seals onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  16. Install the A/C lines (1) and tighten the nuts to the proper torque specifications. Refer to TECHNICAL SPECIFICATIONS .
  17. Install the inlet and outlet hoses to the heater core (2) and connect the quick-connect couplings.
    GC0169971Courtesy of CHRYSLER GROUP, LLC
  18. Install the injector silencer pad (3) over the fuel rail.
  19. Connect fuel line (1) to the fuel rail.
  20. Connect the purge vapor line (2) to the purge solenoid.
    GC0171894Courtesy of CHRYSLER GROUP, LLC
  21. Install the three right engine mount to frame rail bolts (3) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0174096Courtesy of CHRYSLER GROUP, LLC
  22. Connect the Power Takeoff Unit (PTU) wire harness connector (1), if equipped.
    GC0156271Courtesy of CHRYSLER GROUP, LLC
  23. Install the upper intake manifold support bracket (1) with two nuts (2) and two bolts (2) tightened to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0156297Courtesy of CHRYSLER GROUP, LLC
  24. The throttle body gasket (1) can be reused if not damaged.
    GC0155543Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    DO NOT OVER TORQUE. Over tightening can cause damage to the throttle body, gaskets, bolts or the intake manifold.

  25. Install the throttle body (3) to the intake manifold with three bolts (1) and stud bolt (2) finger tight.
    Fig 2: Throttle Body Bolts Tightening Sequence
    GC0080450Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The throttle body must be torqued in a mandatory torque sequence. Tighten in a criss - cross pattern to specification.

  26. Tighten the bolts in criss-cross pattern to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0155590Courtesy of CHRYSLER GROUP, LLC
  27. Install the throttle body support bracket (2) with the nut (1) and bolt (3) tightened to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0155766Courtesy of CHRYSLER GROUP, LLC
  28. Install wire harness retainer (3) to throttle body (2) and connect the throttle body wire harness connector (1).
    GC0156353Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    FWD shown in illustration, 4X4 similar

  29. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  30. Install the lower intake manifold support bracket (3) with two nuts (1) and one bolt (2) tightened to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
  31. Install the rear engine mount insulator. Refer to INSULATOR, ENGINE MOUNT, REAR, REMOVAL AND INSTALLATION .
    GC0171665Courtesy of CHRYSLER GROUP, LLC
  32. Install a new exhaust flange gasket (2) and loosely install the exhaust pipe (1) to the catalytic converter outlet flange with two nuts (3).
  33. Loosely install the exhaust pipe support bolt (4).
  34. Tighten the exhaust pipe flange nuts (3) and the exhaust pipe support bolt (4) to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0169309Courtesy of CHRYSLER GROUP, LLC
  35. Install the MAP sensor (1). Refer to SENSOR, MANIFOLD ABSOLUTE PRESSURE (MAP), REMOVAL AND INSTALLATION .
  36. Engage the two wire harness retainers (2) to the intake manifold.
  37. Install the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
  38. Remove the support and lower the vehicle.
  39. Fill the cooling system. Refer to STANDARD PROCEDURE .
  40. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  41. Install the clean air hose and engine cover. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
  42. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
  43. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  44. Start and run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
  45. Use a scan tool to clear all Diagnostic Trouble Codes (DTC) and perform Electronic Throttle Control (ETC) relearn function.
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