Exhaust Manifold Replacement - Right

Removal Procedure





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Service Precautions.
2. Remove the cross vehicle brace. Refer to Brace Replacement - Cross Vehicle in Body and Frame.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36(VIN K)) or Fuel Injector Sight Shield Replacement (L67 (VIN 1)).
4. Disconnect the exhaust crossover pipe from the right exhaust manifold. Refer to Exhaust Crossover Replacement.
5. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
6. Remove the EGR adapter pipe from the right exhaust manifold.
7. Remove the three way catalytic converter pipe from the right exhaust manifold.
8. Remove the wiring harness and the heater hose retaining clips from the fuel injector sight shield bracket.
9. Remove the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
10. Remove the right engine lift bracket bolt and nut.





11. Remove the right engine lift bracket.
12. Remove the fuel injector sight shield bracket nuts.
13. Remove the fuel injector sight shield bracket. L36 (VIN K) fuel injector sight shield bracket shown.





14. Remove the right exhaust manifold bolts and nuts, except for the bolt behind the oxygen sensor.
15. Lower the vehicle.
16. Rotate the engine.
17. Disconnect the oxygen sensor electrical connector. Refer to HO2S Replacement in Powertrain Management.
18. Remove the remaining bolt and the right exhaust manifold.
19. Remove the right exhaust manifold gasket.





20. Remove the upper right exhaust manifold heat shield.





21. Remove the lower right exhaust manifold heat shield.
22. Remove the heated oxygen sensor from the right exhaust manifold. Refer to HO2S Replacement in Powertrain Management.





23. Remove the exhaust manifold pipe studs) if damaged.

Installation Procedure





1. Install the exhaust manifold pipe stud(s) if removed.
Tighten the exhaust manifold pipe stud(s) to 6 Nm (53 ft. lbs.).
2. Install the heated oxygen sensor to the right exhaust manifold. Refer to HO2S Replacement in Powertrain Management.





3. Install the lower right exhaust manifold heat shield.





4. Install the upper right exhaust manifold heat shield.





5. If replacing the right exhaust manifold, install the heated oxygen sensor to the right exhaust manifold. Refer to HO2S Replacement in Powertrain Management.





6. Install the new right exhaust manifold gasket.
7. Install the right exhaust manifold.
8. Install the right exhaust manifold bolt behind the oxygen sensor.
9. Connect the oxygen sensor electrical connector. Refer to HO2S Replacement in Powertrain Management.
10. Return the engine to the original position.
11. Raise and suitably support the vehicle. Refer to Vehicle Lifting.

Notice: Refer to fastener Notice in Service Precautions.

12. Install the remaining right exhaust manifold bolts and nuts.
Tighten the right exhaust manifold bolts and nuts to 30 Nm (22 ft. lbs.).





13. Install the fuel injector sight shield bracket. L36 (VIN K) fuel injector sight shield bracket shown.
14. Install the fuel injector sight shield bracket nuts.
Tighten the fuel injector sight shield bracket nuts to 30 Nm (22 ft. lbs.).





15. Install the right engine lift bracket.
16. Install the right engine lift bracket bolt and nut.
Tighten the right engine lift bracket bolt and nut to 30 Nm (22 ft. lbs.).
17. Install the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Powertrain Management.
18. Install the wiring harness and the heater hose retaining clips to the fuel injector sight shield bracket.
19. Connect the three-way catalytic converter pipe to the right exhaust manifold.

Important: Whenever the EGR pipe is removed from the right exhaust manifold, the outlet pipe should be inspected for leaks during installation. If leaks are present, replace the EGR adapter.





20. Install the EGR adapter pipe to the right exhaust manifold.
Tighten the EGR adapter pipe bolt to 29 Nm (21 ft. lbs.).
21. Lower the vehicle.
22. Install the exhaust crossover pipe to the right exhaust manifold. Refer to Exhaust Crossover Replacement.
23. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36 (VIN K)) or Fuel Injector Sight Shield Replacement (L67 (VIN 1)).
24. Install the cross vehicle brace. Refer to Brace Replacement - Cross Vehicle in Body and Frame.
25. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Service Precautions.