Exhaust Manifolds

Removal

1. Disconnect battery ground cable (14301).

2. Disconnect the inlet air hose at the crankcase vent filter (6A768). Remove the air cleaner outlet tube (9B659).

3. Remove the accelerator control splash shield (9E766). Disconnect the accelerator cable (9A758) at the throttle body (9E926). Position the accelerator cable out of the way.

4. Disconnect engine control sensor wiring (12A581) from powertrain control module (PCM) (12A650).

5. Disconnect two heated oxygen sensors (HO2S) (9F472).

6. Disconnect the fuel lines from the fuel injection supply manifold (9D280) with Fuel Line Removal Tool T93T-9550-AH. Do not bend the fuel lines.

7. Remove the upper intake manifold (9424) and throttle body.

8. Disconnect all the vacuum lines. Label the lines so they are reinstalled properly.

9. Remove two clips and intake manifold shield (9471).

10. Using a 3/8-inch flex handle, rotate drive belt tensioner (6B209) and remove drive belt (8620).

11. Disconnect generator wiring.

12. Remove two screws, and generator (GEN) (10300).

13. Disconnect air pump hoses.

14. Remove three screws and secondary air injection pump pulley (9B447).

15. Remove two screws and secondary air injection pump (AIR pump) (9A486).

16. Remove nut, three screws, and generator mounting bracket (10153).

    

    Item	Part Number	Description
    1	10300	Generator
    2	8509	Water Pump Pulley
    3	380288-S2	Screw, 5/16-24 x 0.85
    4	390785-S36	Screw, 3/8-16 x 1.25
    5	391319-S2	Bolt, 7/16-14 x 5.5
    6	3191314-S2	Bolt, 3/8-16 x 5.25
    7	56561-S2	Bolt, 7/16-14 x 1.25
    8	N802493-S2	Screw, M6-1.0 x 16
    9	9B447	Secondary Air Injection Pump Pulley
    10	9A486	Secondary Air Injection Pump
    11	56540-S36	Bolt, 3/8-16 x 1.0
    12	56545-S2	Bolt, 3/8-16 x 2.25
    13	382802-S2	Nut, 3/8-16
    A	—	Tighten to 17-23 Nm (13-17 Lb-Ft)
    B	—	Tighten to 22-28 Nm (16-21 Lb-Ft)
    C	—	Tighten to 53-72 Nm (39-53 Lb-Ft)
    D	—	Tighten to 28-42 Nm (21-31 Lb-Ft)
    E	—	Tighten to 12-15 Nm (9-11 Lb-Ft)
    F	—	Tighten to 41-54 Nm (30-39 Lb-Ft)

17. Disconnect the dual converter Y pipe (5F250) and EGR valve to exhaust manifold tube (9D477) from the exhaust manifolds (9430).

18. Disconnect the power brake vacuum line.

19. Remove manifold, rear exhaust manifold and lower intake manifold to the cylinder head (6049). Lift the manifolds from the engine (6007). Remove and discard the gaskets.

Installation

1. Clean the mating surfaces of the cylinder head, front exhaust manifold, rear exhaust manifold, lower intake manifold, and upper intake manifold.

2. NOTE: The EGR valve to exhaust manifold tube is only on the rear exhaust manifold.

   If the rear manifold is to be replaced, remove all fittings from the discarded manifold as required.

3. The exhaust manifold is to be replaced, remove the heated oxygen sensor from the old manifold and install in the new one.

4. Make sure dowel pin is in place.

5. Install rear exhaust manifold with bolts in holes 16 and 15. Tighten bolts to 30-43 Nm (22-32 lb-ft).

6. Install front exhaust manifold and lifting eye with stud in hole 13 and bolt in hole 14. Snug stud and tighten bolt to 30-43 Nm (22-32 lb-ft).

7. Install intake manifold gasket (9439) over dowel pin and line up port openings in the cylinder head and intake manifold gasket.

8. Install the lower intake manifold onto dowel pins, then install remaining bolts.

9. Tighten bolts to 30-43 Nm (22-32 lb-ft) in numerical sequence shown.

   

10. Connect power brake vacuum line.

11. Connect dual converter Y pipe to the front and rear exhaust manifolds. Tighten lockwashers and nuts to 34-49 Nm (25-36 lb-ft).

12. Install generator mounting bracket and three bolts finger-tight. Install nut finger-tight.

    1. Tighten bottom rear bolt to 30-40 Nm (22-30 lb-ft).
    2. Tighten center bolts to 30-40 Nm (22-30 lb-ft).
    3. Tighten nut to 30-40 Nm (22-30 lb-ft).
    4. Tighten bottom front bolt to 30-40 Nm (22-30 lb-ft).

13. Install secondary air injection pump and tighten top bolt to 28-42 Nm (21-31 lb-ft). Tighten bottom bolt to 41-54 Nm (30-39 lb-ft).

14. Install secondary air injection pump pulley and tighten screws to 12-15 Nm (9-11 lb-ft).

15. Connect air pump hoses.

16. Install generator and tighten bottom bolt to 53-72 Nm (39-53 lb-ft). Tighten top bolt to 22-28 Nm (16-21 lb-ft).

17. Connect generator wiring.

18. Position drive belt.

19. Using 3/8-inch flex handle, rotate drive belt tensioner and place accessory drive belt. Slowly release drive belt tensioner onto drive belt tensioning drive belt.

20. Install heat shield and two clips.

    

    Item	Part Number	Description
    1	—	Runner Number 2 (Part of 9424)
    2	9471	Intake Manifold Shield
    3	390717-S56	Spring Clip
    4	—	Runner Number 3 (Part of 9424)
    5	—	Runner Number 4 (Part of 9424)
    6	—	Runner Number 5 (Part of 9424)
    7	9424	Intake Manifold (Lower)
    8	9424	Intake Manifold (Upper)

21. Reconnect all vacuum lines.

22. Install the upper intake manifold and throttle body.

23. Connect fuel lines to fuel injection supply manifold.

24. Connect two heated oxygen sensors.

    

25. Connect engine control sensor wiring to powertrain control module.

26. Connect the accelerator cable to the throttle body.

27. Install accelerator control splash shield.

28. Install air cleaner outlet tube and PVC air inlet hose at the crankcase vent filter.

29. Connect battery ground cable.

    Exhaust Manifold

    

    Item	Part Number	Description
    1	390754	Screw, 3/8-18 x 1.25
    2	9424	Intake Manifold (Lower)
    3	9439	Intake Manifold Gasket
    4	6049	Cylinder Head
    5	—	Dowel Pin, 5/16 x 1.00 (Part of 6049)
    6	9430	Exhaust Manifold, Front
    7	17A084	Lifting Eye
    8	391402	Stud, 3/8-16 x 3.57
    9	390530	Bolt, 3/8-16 x 1.31
    10	9430	Exhaust Manifold, Rear
    11	9F485	EGR Valve Tube to Manifold Connector
    12	—	Hole For Heated Oxygen Sensor
    A	—	Refer to Text for Tightening Instructions