Exhaust Manifold - Installation

INSTALLATION




Left side:
1. Prior to installation, make sure all gasket mating surfaces (1, 2) are clean and free of any debris.
2. Using a new exhaust manifold gasket, position the exhaust manifold to the cylinder head, align the gasket and start two upper retaining blots finger tight.





3. Using the sequence shown, Install the exhaust manifold retaining bolts and tighten to 25 Nm (18 ft. lbs.).




Right side:

NOTE: Left side shown, right similar.

4. Prior to installation, make sure all gasket mating surfaces (1, 2) are clean and free of any debris.
5. Using a new exhaust manifold gasket, position the exhaust manifold to the cylinder head, align the gasket and start two upper retaining blots finger tight.





6. Using the sequence shown, install the exhaust manifold retaining bolts and tighten to 25 Nm (18 ft. lbs.).
7. Install the heat shields and tighten nuts to 8 Nm (70 in. lbs.).





8. Position the wire harness mounted onto the right hand inner fender panel and secure fasteners.
9. Install the Totally Integrated Power Module (TIPM) and mounting bracket Totally Integrated Power Module (TIPM) - Installation.





10. Position the coolant bottle (1) and install the retaining bolts (2).
11. Raise and support the vehicle.

CAUTION: Over or under tightening the knock sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control.






NOTE: Left side shown, right side similar.

12. Position both knock sensors (1) onto the engine block.

NOTE: The foam strip used on bolt threads is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.

13. Install both knock sensor retaining bolts (2) and tighten to 20 Nm (15 ft. lbs.).
14. Connect both knock sensor electrical connectors (3).
15. Snap the heat shields onto both knock sensors.





16. Install both catalytic converters (4) Catalytic Converter - Installation.





17. Install both front engine mount mounting brackets and engine mounts (2) Engine Mount Insulator - Installation.





18. Install both catalytic converters (4) Catalytic Converter - Installation.

19. Connect the oxygen sensor electrical connectors (2).
20. Lower the vehicle.




21. Position the air filter housing into the engine compartment.
22. Install the air filter housing retaining bolt (3) and tighten to 5 Nm (44 in. lbs.).
23. Connect the clean air tube to the throttle body and the air filter housing and tighten clamps to 3 Nm (30 in. lbs.).
24. Connect the make up air hose (MUA) (2).
25. Connect the intake air temperature (IAT) sensor (5) connector.





26. Position the engine cover (2) and secure the retaining grommets onto the ball studs.





27. Connect the negative battery cable and tighten nut (1) to 5 Nm (45 in. lbs.).
28. Start the engine and check for leaks.