Removal and Installation

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

1. Perform fuel pressure release procedure.
2. Disconnect negative cable from battery.
3. Disconnect fuel supply line at the fuel tube.
4. Remove air cleaner assembly and bracket.
5. Remove fasteners attaching power steering reservoir bracket to cylinder head. Set reservoir aside.

Figure 23:

6. Remove exhaust manifold upper heat shield.
7. Disconnect upstream heated oxygen sensor connector.
8. Hoist vehicle and remove right side splash shield.
9. Loosen generator drive belt.

Figure 24:

10. Remove generator spill shield.
11. Remove exhaust pipe from manifold. Discard manifold to flex joint gasket, if LEV equipped.
12. Remove lower exhaust manifold heat shield.

Figure 25:

13. Remove lower exhaust manifold retaining fasteners.
14. Lower vehicle and remove upper exhaust manifold retaining fasteners.
15. Remove manifold and gasket.

INSTALLATION

NOTE: Discard gasket and clean all gasket surfaces of manifolds and cylinder head.

1. Position exhaust manifold and gasket in place. Apply Mopar(R) Stud and Bearing Mount to fasteners and tighten to 23 Nm (200 inch lbs.) starting at center and progressing outward in both directions. Repeat this procedure until all fasteners are at specified torque.
2. Install exhaust manifold lower and upper heat shields.
3. Install generator spill shield.
4. Attach power steering reservoir and bracket to cylinder head.
5. Tension generator belt.
6. Connect upstream heated oxygen sensor connector.
7. Replace manifold to flex joint gasket, if LEV equipped.
8. Attach exhaust pipe and tighten fasteners to 28 Nm (250 inch lbs.).
9. Install right side splash shield.
10. Inspect quick connect fuel line fitting for damage-replace if necessary. Apply a light amount of clean engine oil to fuel inlet tube. Connect fuel supply hose to fuel tube. Check connection by pulling on connector to ensure it locked into position.
11. Install air cleaner bracket and assembly.
12. Connect negative cable to battery.