A. Intake Manifold Removal and Dash Panel Silencer Pad Inspection

1. Using Mopar Foamy Engine Degreaser (P/N 04318040AB), wash the engine. Be sure to thoroughly clean the areas around the fuel filter, fuel rail and front of the engine.

2. Disconnect and isolate the negative battery cable.

3. Drain the engine coolant from the cooling system.





4. Remove the engine fuel injector cover from the engine (Figure 1).

5. Remove the intake manifold charge air hose (Figure 1).

NOTE:
Place a shop towel in the mass airflow sensor opening to prevent debris from entering the mass airflow sensor opening.

6. Remove and save the Exhaust Gas Recirculation (EGR) mixing chamber from the intake manifold (Figures 1 and 2).





7. Remove the intake manifold upper steel support bracket from the engine (Figure 2).

8. Remove the two bolts from the rear aluminum intake manifold support bracket (Figure 2).

9. Using Special Tool 9285, remove the five injector rail-to-injector crossover tubes (Figure 2). Place rubber caps over all open fuel ports.

10. Remove the upper radiator hose.

11. Remove the radiator coolant recovery bottle hose.

12. Remove the brake booster vacuum hose from the vehicle (Figure 2).





13. Remove and cap the inboard fuel hose at the fuel filter (Figure 3).

14. Remove and cap the center fuel tube at the fuel filter (Figure 3).

15. Remove fuel tube at fuel pressure sensor located on the bottom side of the intake manifold.

NOTE:
The fuel tube quick connect disengages by pushing and holding the white horse shoe clip while carefully wiggling the fuel tube quick connector from the sensor port. All quick connects disengage using this technique.

16. Remove the fuel filter and bracket as an assembly from the frame and set aside.





17. Remove and save the steel high pressure pump-to-fuel rail tube (Figure 4). Place rubber caps over open fuel ports.

18. Disconnect the heater hose at the lower intake manifold support bracket.

19. Remove the lower intake manifold support bracket.

20. Remove the engine wiring harness from the vehicle using the following procedure:





a. Disconnect the three engine electrical wiring harness connectors located under the instrument panel (Figure 5).

b. Disengage the dash panel engine electrical harness rubber grommet from the dash panel (Figure 5).

c. Pull the harness out of the dash panel opening (Figure 5).

d. Cut and discard the engine electrical harness tie straps that hold the engine harness to the main wiring harness.

e. Disconnect the ABS module connectors located under the battery.





f. Disconnect all underhood connectors that are related to the engine harness (Figure 6).

g. Disconnect the engine harness retaining bolts.

h. Using Special Tool 9286, disconnect the five glow plug electrical connectors from the glow plugs (Figure 6).

i. Disconnect the electrical connectors at the five fuel injectors (Figure 6).

j. Carefully remove the entire engine electrical harness assembly from the vehicle (Figure 6).

21. Remove the intake manifold mounting bolts.

NOTE:
All bolts are accessible without having to remove or loosen the fuel rail. Some bolts are accessed from the top and others from under the vehicle.

22. Carefully remove the intake manifold from the vehicle.

23. Inspect the dash panel silencer pad for burn holes or damage:





> If no burn holes or damage is found on the dash panel silencer pad in the area shown in Figure 7, continue with Section C - Intake Manifold Installation.

> If the dash panel silencer pad is damaged or burned in the area shown in Figure 7, continue with Section B - Dash Panel Silencer Pad Replacement.