Exhaust Manifold Replacement - Right Side L47

Tools Required

J 42640 Steering Column Lock Pin

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

1. Disconnect the heated oxygen sensor at the sensor pigtail.




Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

2. Lock the steering column by installing the J 42640 into the underside of the steering column.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .



5. Remove the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).
6. Remove the secondary AIR tube (1) and the gasket from the exhaust manifold (3). Do not reuse the gasket.



7. Disconnect the post heated oxygen sensor wiring harness retainer from the power steering gear heat shield.
8. Remove the two bolts securing the heat shield.
9. Remove the heat shield from the power steering gear.



10. Remove the rearward nut (3) securing the vehicle speed sensor heat shield (1).
11. Loosen the forward nut (2) in order to remove the heat shield (1).
12. Remove the heat shield (1) from the transaxle.




Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

13. Remove the intermediate shaft pinch bolt.
14. Disconnect the intermediate shaft from the steering gear.



15. Remove the nut securing the right engine mount to the right engine mount bracket.



16. Remove the nut securing the left transaxle mount to the left transaxle mount bracket.



17. Support the rear of the engine frame with a tall screw jack.
18. Remove the four rearward engine frame-to-body bolts.
19. Lower the screw jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.
20. Remove the heated oxygen sensor if replacement is necessary. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 in Engine Controls - 4.0 L.



21. Remove the right exhaust manifold retaining nuts.
22. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
23. Clean and inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection - Right Side in Engine Mechanical-4.0L Unit Repair.

1. Place a NEW exhaust manifold gasket over the cylinder head studs.
2. Position the right exhaust manifold to the right cylinder head.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the right exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 25 N·m (18 lb ft).

4. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 in Engine Controls - 4.0 L.



5. Raise the engine cradle into position.
6. Install the four rearward engine frame-to-body bolts.

Tighten
Tighten the engine frame bolts to 191 N·m (141 lb ft).

7. Remove the screw jack.



8. Install the nut securing the left transaxle mount to the left transaxle mount bracket.

Tighten
Tighten the transaxle mount nut to 80 N·m (59 lb ft).




9. Install the nut securing the right engine mount to the right engine mount bracket.

Tighten
Tighten the engine mount nut to 80 N·m (59 lb ft).





Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

10. Connect the intermediate shaft to the steering gear.
11. Install the intermediate shaft pinch bolt.

Tighten
Tighten the intermediate shaft pinch bolt to 45 N·m (33 lb ft).




12. Position the vehicle speed sensor heat shield (1) to the studs on transaxle.
13. Install the retaining nuts (2, 3) securing the vehicle speed sensor heat shield to the transaxle.

Tighten
Tighten the vehicle speed sensor heat shield nuts to 50 N·m (37 lb ft).




14. Position the power steering gear heat shield to the power steering gear.
15. Install the two bolts securing the heat shield.

Tighten
Tighten the power steering gear heat shield bolts to 9 N·m (79 lb in).

16. Connect the post heated oxygen sensor wiring harness retainer to the heat shield.



17. Install the new gasket to the secondary AIR tube (1).
18. Install the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).

Tighten
Tighten the secondary AIR tube nuts to 12 N·m (106 lb in).

19. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
20. Lower the vehicle.



21. Remove the J 42640 from the steering column.
22. Connect the heated oxygen sensor at the sensor pigtail.