Replacement

REMOVAL
1. Disconnect battery ground cable (14301).
2. On LH exhaust manifold (9430), remove bolt retaining oil level indicator tube (6754).
3. Raise vehicle on hoist.
4. Disconnect fuel charging wiring (9D930) from heated oxygen sensors (HO2S)(9F472).
5. Remove EGR valve to exhaust manifold tube line nut from RH exhaust manifold and remove EGR valve to exhaust manifold tube (9D477).
6. Disconnect three way catalytic converter (TWC)(5E212) from RH and LH exhaust manifold.





7. Lower three way catalytic converter and secure to crossmember with wire in positions shown.
8. For LH exhaust manifold, disconnect the steering shaft and position out of the way.





9. Remove eight nuts retaining LH exhaust manifold and remove LH exhaust manifold and two exhaust manifold caskets (9448).
10. For RH exhaust manifold, remove eight nuts retaining exhaust manifold to cylinder head (6049) and studs and remove RH exhaust manifold and exhaust manifold gasket.

INSTALLATION
1. If RH exhaust manifold is being replaced, transfer EGR valve tube to manifold connector (9F485) and tighten to 45-65 Nm (34-47 ft. lbs.).
2. Clean mating surfaces of exhaust manifolds and cylinder heads.





3. Position exhaust manifold gasket and LH exhaust manifold to cylinder head and studs and install eight retaining nuts. Tighten in sequence to 18-22 Nm (14-16 ft. lbs.).
4. Position two exhaust manifold gaskets and LH exhaust manifold to cylinder head and studs and install eight retaining nuts. Tighten in sequence to 18-22 Nm (14-16 ft. lbs.). Refer to illustration.
5. Position and connect steering shaft.
6. Position and connect EGR valve to exhaust manifold tube to exhaust manifold. Tighten line nut to 35-45 Nm (26-33 ft. lbs.).

NOTE: Loosen line nut at EGR valve (EGR valve)(9D475) prior to installing assembly into vehicle. This will allow enough movement to align EGR valve retaining bolts.

7. Remove wire and position three way catalytic converter. Install four nuts and tighten to 27-41 Nm (20-30 ft. lbs.).

NOTE:
^ Two through bolts required on LH front engine support insulator (6038) and one through bolt required on RH front engine support insulator.
^ Make sure exhaust system clears No.3 crossmember. Adjust as necessary.

8. Connect fuel charging wiring to heated oxygen sensors.
9. Lower vehicle.
10. Connect battery ground cable.
11. Start engine and check for exhaust leaks.