Exhaust Manifold - Installation

INSTALLATION





1. If removed, install the upstream (2) and downstream (3) oxygen sensor(s) to the maniverter Oxygen Sensor - Installation.
2. Clean the mating surfaces of the cylinder head and the maniverter flange.
3. Install a new maniverter gasket on the cylinder head.

CAUTION: The maniverter studs are installed in the cylinder head with a thread sealant. If the studs rotate during service this indicates that the seal is broken and the stud must be replaced. Failure to replace the studs can result in engine oil leaking onto the exhaust manifold.

4. Mark the end of the nine maniverter mounting studs with a paint pen or equivalent to indicate possible stud rotation.
5. Guide the maniverter (4) into place onto the studs. Install and tighten the nine nuts (1) to 20 Nm (15 ft. lbs.).
6. Check the markings on the studs for indication of rotation. If there is evidence of stud rotation, replace the stud Exhaust Manifold Stud Replacement.
7. Engage the wire harness retainers and connect the upstream (2) and downstream (3) oxygen sensor electrical connectors.





8. Install the maniverter heat shield (2) with four bolts (3) and two nuts (1). Tighten the nuts (1) and bolts (3) to 9 Nm (80 in. lbs.).





9. Raise and support the vehicle Maintenance.
10. Install the muffler flexible intake pipe to the maniverter flange with two nuts (1). Tighten the nuts (1) to 25 Nm (18 ft. lbs.).
11. Install the maniverter pipe extension support to the oil pan. Tighten the bolt (2) to 50 Nm (37 ft. lbs.).





12. Install the front cooling module assembly (4) with four bolts (1), eight bolts and washers (2) and eight bolts and washers (3). Tighten the eight bolts (2) to 45 Nm (33 ft. lb.). Tighten the four bolts (1) to 24 Nm (18 ft. lb.). Tighten the eight bolts (3) to 45 Nm (33 ft. lb.).





13. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.





14. Engage the wire harness connector (1) to the bumper reinforcement.





15. Connect the harness connector (2) to the horn (1).





16. Connect the harness connector (1) to the right and left front impact sensors (3) Front.





17. Press down the latch release (3) and install the hood latch cable (2) to the latch.





18. Engage the A/C liquid line (1) to the A/C discharge line (2) and connect the lines to the A/C condenser tapping block (3) using new dual plain seals lubricated with clean refrigerant oil. Install the retaining bolt (4) and tighten to 14 Nm (10 ft. lbs.).





19. Connect the lower coolant hose to the radiator.
20. Connect the cooling fan harness connector (3).





21. Connect the upper coolant hose to the radiator.
22. Connect the harness connector to the cooling fan resistor (1).





23. Install the right and left headlamp units (2) Headlamp Unit - Installation.





24. Install the front fascia (1) Front Bumper Fascia - Installation.
25. Install both front inner wheel well splash shields Splash Shield - Installation.
26. Install both front tire and wheel assemblies Tires And Wheels - Installation.





27. Remove the four bolts (1) and install the tunnel support brace (2). Reinstall the four bolts (1) and tighten to 90 Nm (60 ft. lb.).





28. Install the belly pan Belly Pan - Installation.





29. Lower the vehicle.
30. Install the air cleaner body (6) Air Cleaner Body - Installation.





31. Fill the cooling system Service and Repair.
32. Connect the negative battery cable. Tighten nut to 5 Nm (45 in. lb.).
33. Evacuate and charge the refrigerant system Refrigerant System Charge.
34. Install the engine cover (1).
35. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair.