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MANIFOLD - EXHAUST
DESCRIPTION
The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust
manifolds are made of high silicon molybdenum cast iron. A perforated coregraphite exhaust manifold gasket is
used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat
shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is
backed off slightly to allow for the thermal expansion of the exhaust manifold.
OPERATION
The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust
gases to the exhaust pipes attached to the manifolds.
REMOVAL
EXHAUST MANIFOLD
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1. Disconnect negative battery cable.
2. Raise vehicle.
3. Remove exhaust pipe to manifold bolts.
4. Lower vehicle.
5. Install engine support fixture special tool #8534.
6. Raise engine enough to remove manifolds.
CAUTION: Do not damage engine harness while
raising the engine.
7. Remove heat shield.
8. Remove manifold bolts using sequence provided.
9. Remove manifold and gasket.
CLEANING
Clean mating surfaces on cylinder head and manifold. Wash with solvent andblow dry with compressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per
300 mm (0.008 inch per foot).
INSTALLATION
EXHAUST MANIFOLD
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1. Install manifold gasket and manifold.
2. Install manifold bolts and tighten using sequence
provided to 25 Nꞏm (18 ft. lbs.).
3. Install heat shield and tighten nuts to 15 Nꞏm (11 ft.
lbs.).
4. Lower engine.
CAUTION: Do not damage engine harness while
lowering the engine.
5. Remove engine support fixture from engine.
6. Raise vehicle.
7. Tighten right and left side engine mount through
bolts.
8. Install exhaust flange to pipe bolts.
9. Lower vehicle.
10. Connect negative battery cable.
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COVER - TIMING
REMOVAL
1. Disconnect the battery negative cable.
2. Remove the engine cover (1).
3. Remove air cleaner assembly.
4. Drain cooling system.
5. Remove accessory drive belt.
6. Remove fan and fan drive assembly (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
7. Remove coolant bottle and washer bottle.
8. Remove fan shroud.
NOTE: It is not necessary to disconnect A/C lines
or discharge freon.
9. Remove A/C compressor and set aside.
10. Remove the generator.
11. Remove upper radiator hose.
12. Disconnect both heater hoses at timing cover.
13. Disconnect lower radiator hose at engine.
14. Remove accessory drive belt tensioner and both
idler pulleys.
15. Remove crankshaft damper (2) (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
NOTE: Do not remove the hoses from the power
steering pump.
16. Remove power steering pump and set aside.
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17. Remove the dipstick support bolt.
18. Drain the engine oil.
19. Remove the oil pan and pick up tube (Refer to 9 - ENGINE/LUBRICATION/OILPA N - R E M O VA L ) .
NOTE: It is not necessary to remove water pump for timing cover removal.
20. Remove timing cover bolts and remove cover.
21. Verify that timing cover slide bushings (1) are located in timing cover.
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INSTALLATION
1. Clean timing chain cover and block surface.
NOTE: Always install a new gasket on timing cover.
2. Verify that the slide bushings (1) are installed in timing cover.
3. Install cover and new gasket. Tighten fasteners to 28 Nꞏm (250 in. lbs.).
NOTE: The large lifting stud is torqued to 55 Nꞏm (40 ft. lbs.).
4. Install the oil pan and pick up tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
5. Install the A/C compressor.
6. Install the generator.
7. Install power steering pump.
8. Install the dipstick support bolt.
9. Install the thermostat housing.
10. Install crankshaft damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
11. Install accessory drive belt tensioner assembly
and both idler pulleys.
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12. Install radiator lower hose.
13. Install both heater hoses.
14. Install radiator fan shroud.
15. Install the fan and fan drive assembly
16. Install the accessory drive belt.
17. Install the coolant bottle and washer bottle.
18. Install the upper radiator hose.
19. Install the air cleaner assembly.
20. Fill cooling system.
21. Refill engine oil.
22. Connect the battery negative cable.
23. Install the engine cover (1).
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TIMING CHAIN & SPROCKETS
REMOVAL
1. Disconnect battery negative cable.
2. Drain cooling system.
3. Remove Timing Chain Cover (1).
4. Re-install the vibration damper bolt finger tight.
Using a suitable socket and breaker bar, rotate the
crankshaft to align timing chain sprockets and key-
ways as shown.
CAUTION: The camshaft pin and the slot in the
cam sprocket must be clocked at 12:00 (2). The
crankshaft keyway must be clocked at 2:00 (3).
The crankshaft sprocket must be installed so that
the dots and or paint marking is at 6:00.