Exhaust Manifold Replacement (Passenger Side)

REMOVAL PROCEDURE

^ Tools Required
- J28467-A Engine Support Fixture





1. Remove the radiator cradle beauty panel.
2. Remove the air cleaner assembly.
3. Remove the engine cooling fans.
4. Install the J 28467-A.
5. Raise the vehicle on the hoist.
6. Remove the two nuts securing the motor mount to the engine frame.
7. Remove the two bolts securing the motor mount bracket to the crankcase.
8. Remove the two bolts securing the motor mount bracket to the cylinder head.
9. Remove the two nuts securing the motor mount to the mount bracket.
10. Lower the vehicle.
11. Raise the engine by adjusting the engine support fixture.
12. Remove the motor mount and the bracket.
13. Raise the vehicle.
14. Remove the four bolts securing the rear generator bracket.





15. Remove the two bolts at the manifold outlet flange (2).
16. Disconnect the oxygen sensor wire.





17. Remove the exhaust manifold bolts.
18. Remove the manifold and the gasket. Discard the gasket.
19. Remove the oxygen sensor if replacement is necessary.

INSTALLATION PROCEDURE





1. Install the exhaust manifold by inserting the outlet pipe partially into the exhaust crossover pipe.
2. Move the manifold into position.
3. Install the gasket to the manifold. Hold the gasket in position by inserting two bolts.
4. Start the remainder of the manifold bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





5. Coat the oxygen sensor threads with high-temperature anti-seize, P/N 5613695 or equivalent.
6. Install the sensor.
^ Tighten the nut to 40 N-m (30 ft. lbs.).

7. Connect the exhaust oxygen sensor.
8. Install the rear generator bracket.
^ Tighten the crankcase bolts to 60 Nm (44 ft. lbs.).
^ Tighten the generator bolts to 30 Nm (22 ft. lbs.).

9. Position the motor mount and the bracket.
10. Loosely install two nuts securing the mount to the bracket.
11. Lower the vehicle.
12. Loosely install two bolts to the mount bracket at the cylinder head.
13. Lower the engine to the installed position guiding the motor mount studs in the cradle holes.
14. Raise the vehicle.
15. Loosely install two nuts to the bottom of the motor mount.
16. Loosely install two bolts securing the mount bracket to the crankcase.
^ Tighten the fasteners in steps 12, 17 and 18 to 30 Nm (22 ft. lbs.).

17. Install the rear generator bracket.
^ Tighten the four screws to 50 Nm (37 ft. lbs.).

18. Lower the vehicle.





19. Remove the J 28467-A.
^ Tighten the fasteners installed in step 14 to 30 Nm (22 ft. lbs.).

20. Install the engine cooling fans.
21. Install the air cleaner assembly.
22. Install the radiator cradle beauty cover.