Exhaust Manifold - Installation

INSTALLATION

EXHAUST MANIFOLD - LEFT SIDE





1. Prior to installation, make sure all gasket mating surfaces (1, 2) are clean and free of any debris.
2. Inspect the exhaust manifold (2) for any damage. Exhaust Manifold - Inspection

NOTE: The exhaust manifold is installed from below the engine compartment.

3. Raise and support the vehicle.

NOTE: Make sure gasket is properly seated before tightening the manifold stud/bolts.

4. Position the exhaust manifold gasket and manifold (2) and hand tighten the eight bolts/studs.





5. Lower the vehicle.
6. Using the sequence shown, tighten the exhaust manifold eight retaining bolts/studs to 25 Nm (18 ft. lbs.).





7. Raise and support the vehicle.
8. Position the exhaust manifold heat shield.
9. Install the two rear exhaust manifold heat shield retaining nuts (1) and tighten to 8 Nm (71 in. lbs.).





10. Install the lower dipstick stud/bolt (3) located in front of the starter (1) and tighten to 12 Nm (9 ft. lbs.)
11. Install the battery ground harness retaining nut (2) located in front of the starter (1) and tighten the to 11 Nm (8 ft. lbs.).
12. Install the bolts at the left front exhaust pipe/catalytic converter assembly to exhaust manifold flange. Do not tighten.
13. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
14. Once properly aligned, tighten the left front exhaust pipe/catalytic converter assembly to exhaust manifold bolts to 26 Nm (19 in. lbs.).
15. Tighten the right front exhaust pipe/catalytic converter assembly to the exhaust manifold bolts to 26 Nm (19 in. lbs.).





16. Install the two bolts and two nuts from the intermediate steering shaft support bracket (2) to the frame and tighten the bolts to 12 Nm (9 ft. lbs.).





17. Install the left front left wheelhouse splash shield (2) Front Fender Liner.
18. Install any skid plates (if equipped).
19. Install the front tire and wheel.
20. Lower the vehicle.
21. Install the two front exhaust manifold heat shield retaining nuts (1) and tighten to 8 Nm (71 in. lbs.).
22. Install the dipstick tube upper mounting bolt and tighten to 12 Nm (9 ft. lbs.).





23. Install the lower coupling pinch bolt (1) through the intermediate steering shaft (2) to the rack and pinion assembly (3) and tighten the bolt (1) to 49 Nm (36 ft. lbs.).






CAUTION: Use caution when connecting, disconnecting or repositioning any wiring harness. Damage could occur to the wiring harness due to vehicle mileage, vehicle age and environmental conditions.

24. Position the main harness.
25. Install the Power Distribution Center (PDC) (1) and the Integrated Power Module (IPM) (2) Power Distribution Module.
26. Connect all remaining connectors to the main harness.
27. Install the battery tray Battery Tray.
28. Install the battery Removal and Replacement.





29. Install the EVAP canister purge solenoid (1).
30. Connect the electrical connector (2) to the EVAP canister purge solenoid.





31. Rotate the strut tower support beam rearward into position.





32. Install the left side strut tower support beam retaining nuts (1) and tighten to 95 Nm (70 ft. lbs.).





33. Install the right side strut tower support beam retaining nuts (1) 95 Nm (70 ft. lbs.).
34. Install the engine cover and resonator Air Cleaner Housing.
35. Start the engine and check for leaks.

EXHAUST MANIFOLD - RIGHT SIDE





1. Prior to installation, make sure all gasket mating surfaces are clean and free of any debris.
2. Inspect the exhaust manifold for any damage Exhaust Manifold - Inspection.

NOTE: The exhaust manifold is installed from below the engine compartment.

3. Raise and support the vehicle.
4. Position the exhaust manifold gasket and manifold from below the engine compartment.

NOTE: Make sure gasket is properly seated before tightening the manifold stud/bolts.

5. Using the sequence shown, install the eight manifold studs/bolts and tighten to 25 Nm (18 ft. lbs.).
6. Install the bolts and nuts at the right front exhaust pipe/catalytic converter assembly to exhaust manifold flange. Do not tighten.
7. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
8. Once properly aligned, tighten the right front exhaust pipe/catalytic converter assembly to exhaust manifold bolts to 26 Nm (19 in. lbs.).
9. Tighten the left front exhaust pipe/catalytic converter assembly to the exhaust manifold bolts to 26 Nm (19 in. lbs.).
10. Install and connect the upstream O2 sensor to the exhaust pipe/catalytic converter assembly Oxygen Sensor.
11. Install any skid plates (if equipped).





12. Install the right front side wheelhouse splash shield (left side shown, right side similar) Front Fender Liner.
13. Install the front tire and wheel.
14. Lower the vehicle.
15. Install the exhaust manifold heat shield and tighten the nuts to 8 Nm (71 in. lbs.).





16. If required, Position and connect the heater hoses to the heater core tubes in the engine compartment.

CAUTION: Use caution when connecting, disconnecting or repositioning any wiring harness. Damage could occur to the wiring harness due to vehicle mileage, vehicle age and environmental conditions.

17. Position and connect the upper right side engine harness.
18. Install the coolant recovery bottle (1) Coolant Reservoir.





19. Install the air box assembly (2) and resonator Air Cleaner Housing.
20. Fill the cooling system Service and Repair.
21. Connect the negative battery cable.
22. Install the engine cover.
23. Start the engine and check for leaks.