Removal and Replacement

Exhaust Manifold





RH Splash Shield









Coolant Hoses and Oil Level Indicator and Tube









Generator and Bracket









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. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

3. Remove the accessory drive belt. For additional information, refer to Accessory Drive [1][2]Diagrams.

4. Drain the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.

5. Remove the 2 exhaust downpipe flange nuts.

6. Disconnect the upper radiator hose and the degas bottle coolant hose from the front coolant outlet pipe.

7. If equipped, remove the A/C compressor. For additional information, refer to Climate Control Service and Repair.

8. Disconnect the heater coolant hose from the front coolant outlet pipe.

9. Remove the oil level indicator, the 2 bolts and the oil level indicator tube.
- Discard the O-ring seal.

10. Remove the 2 bolts and the front coolant outlet pipe.
- Discard the O-ring seal.





11. Remove the 5 pushpins and position the right inner fender splash shield aside.

12. Disconnect the generator electrical connections and, if equipped with A/C, the wiring harness retainer.

13. Remove the 5 bolts and the generator and support bracket assembly.

14. Remove the 2 nuts and position the coolant tube aside.

15. Remove the 7 nuts, the exhaust manifold and the gasket.
- Discard the exhaust manifold nuts and the gasket.

16. Remove and discard the 7 exhaust manifold-to-cylinder head studs.

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

18. 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.

Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging. Observe all warnings and cautions and follow all application directions contained on the packaging of the metal surface prep.

Installation

1. Install 7 new exhaust manifold-to-cylinder head studs.
- Tighten to 17 Nm (150 lb-in).

2. Install a new exhaust manifold gasket.

3. Position the exhaust manifold and install 7 new nuts.
- Tighten to 54 Nm (40 lb-ft).

4. Position the coolant tube and install the 2 nuts.
- Tighten to 20 Nm (177 lb-in).

5. Position the generator and support bracket assembly and install the 5 bolts in the sequence shown, in 2 stages.
- Stage 1: Install finger-tight.

- Stage 2: Tighten to 47 Nm (35 lb-ft).





6. Connect the generator electrical connections and, if equipped with A/C, the wiring harness retainer.
- Tighten the battery cable nut to 12 Nm (106 lb-in).

7. Position the right inner splash shield and install the 5 pushpins.

8. NOTE: Lubricate the new O-ring seal with clean engine coolant prior to installation.

Using a new O-ring seal, position the front coolant outlet pipe and install the 2 bolts.

- Tighten to 25 Nm (18 lb-ft).





9. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Using a new O-ring seal, position the oil level indicator tube assembly and install the 2 bolts.

- Tighten to 10 Nm (89 lb-in).

10. Install the oil level indicator.

11. Connect the heater coolant hose to the front coolant outlet pipe.

12. If equipped, install the A/C compressor. For additional information, refer to Climate Control Service and Repair.

13. Connect the upper radiator hose and the degas bottle coolant hose to the front coolant outlet pipe.

14. Install the 2 exhaust downpipe flange nuts.
- Tighten to 40 Nm (30 lb-ft).

15. Install the accessory drive belt. For additional information, refer to Accessory Drive [1][2]Diagrams.

16. Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

17. Fill and bleed the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.