Exhaust Manifold - RH

Exhaust Manifold - RH









RH Exhaust Manifold









Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Recover the refrigerant. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

3. If equipped, remove the 4 nuts and the strut tower cross brace.





4. NOTE: The engine appearance cover rubber grommets may remain on the cover. If so, remove the grommets from the cover and install them on the intake manifold before installing the cover.

Remove the engine appearance cover.





5. Remove the bolt and position the sound enhancement pipe aside.





6. Remove the 8 pin-type retainers and the upper radiator sight shield.





7. Remove the A/C compressor fitting nut and disconnect the fitting.
- Discard the O-ring seals and gasket seals.





8. Remove the battery tray. For additional information, refer to Battery, Mounting and Cables Battery and Battery Tray - Exploded View.

9. Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.





10. Install an Engine Lifting Bracket on the rear of the RH cylinder head.





11. NOTE: The draw screw and bracket from the heavy duty Engine Support Bar (303-F070) must be used with the light duty Engine Support Bar (303-F072). This will provide enough clearance between the draw screw bracket and the cowl.

Install the Engine Support Bar.





12. NOTE: RH shown, LH similar.

Remove the RH and LH engine support insulator nuts.





13. Using the Engine Support Bar, raise the engine 25 mm (0.984 in).

14. Remove the 4 nuts (2 shown) and the front crossmember brace.





15. Remove the RH catalytic converter. For additional information, refer to Exhaust System [1][2]Catalytic Converter.

16. Remove the starter. For additional information, refer to Starting System Service and Repair.

17. Remove the 3 bolts and lower the underbody shield.





18. Remove the transmission fluid cooler tube nut and bracket from the flexplate inspection cover stud bolt.





19. Remove the nut from the RH engine support insulator bracket stud bolt and position the transmission cooler tube clamp aside.





20. Detach the wiring harness retainers from the RH side of the oil pan and the RH engine support insulator bracket stud bolt.





21. Remove the nut and ground strap from the RH engine support insulator bracket.





22. NOTE: The RH engine support insulator has been removed from the graphic for clarity.

Remove the 2 bolts, the 2 stud bolts and the RH engine support insulator bracket.





23. Remove the 8 nuts and the RH exhaust manifold.
- Discard the gasket.

24. Clean and inspect the RH exhaust manifold. For additional information, refer to Engine System - General Information Exhaust Manifold Cleaning and Inspection.

25. Remove and discard the 8 RH exhaust manifold studs.

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.

2. Install 8 new RH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).

3. NOTE: The tightening specification differs between early build (coarse thread) and late build (fine thread) exhaust manifold nuts.

Install new gaskets, the RH exhaust manifold and 8 new nuts.

- Tighten early build (coarse thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 28 Nm (21 lb-ft).

- Stage 2: Tighten to 37 Nm (27 lb-ft).

- Tighten late build (fine thread) nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).

- Stage 2: Tighten to 32 Nm (24 lb-ft).





4. NOTE: The engine support insulator bracket must be positioned on the engine support insulator stud. If necessary, adjust the height of the engine using the engine support bar.

Install the RH engine support insulator bracket, the 2 bolts and the 2 stud bolts.

- Tighten to 55 Nm (41 lb-ft).





5. Install the ground strap and the nut to the RH engine support insulator bracket.
- Tighten to 48 Nm (35 lb-ft).





6. Attach the wiring harness retainers to the RH side of the oil pan and the RH engine support insulator bracket stud bolt.





7. Install the transmission cooler tube clamp and nut to the RH engine support insulator bracket.
- Tighten to 48 Nm (35 lb-ft).





8. Install the transmission fluid cooler tube bracket and nut to the flexplate inspection cover stud bolt.
- Tighten to 13 Nm (115 lb-in).





9. Position the underbody shield and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





10. Install the starter. For additional information, refer to Starting System Service and Repair.

11. Install the RH catalytic converter. For additional information, refer to Exhaust System [1][2]Catalytic Converter.

12. Install the front crossmember brace and the 4 nuts (2 shown).
- Tighten to 48 Nm (35 lb-ft).





13. Using the Engine Support Bar, lower the engine onto the engine support insulators.

14. NOTE: RH shown, LH similar.

Install the RH and LH engine support insulator nuts.

- Tighten to 63 Nm (46 lb-ft).





15. Connect the RH HO2S electrical connector.





16. Install the battery tray. For additional information, refer to Battery, Mounting and Cables Battery and Battery Tray - Exploded View.

17. Using a new O-ring seal and gasket seal, connect the A/C compressor fitting and install the nut
- Tighten to 15 Nm (133 lb-in).





18. Position the sound enhancement pipe and install the bolt.
- Tighten to 8 Nm (71 lb-in).





19. Install the upper radiator sight shield and the 8 pin-type retainers.





20. NOTE: The engine appearance cover rubber grommets may remain on the cover. If so, remove the grommets from the cover and install them on the intake manifold before installing the cover.

Install the engine appearance cover.





21. If equipped, install the strut tower cross brace and the 4 nuts.
- Tighten to 35 Nm (26 lb-ft).





22. Recharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.