Installation - Light Duty

Fig 1: Locating Exhaust Manifold & Gasket

Courtesy of CHRYSLER GROUP, LLC

Left side shown in illustration, right similar. 

1. Prior to installation, make sure all gasket mating surfaces (1, 2) are clean and free of any debris.
2. Position the exhaust manifold gasket and manifold to the engine.
   Fig 2: Locating Exhaust Manifold Bolts & Washers Placement Locations

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   A special coating is used on the bolts and washers for extreme heat. Placement of the bolts and washers are crucial for expansion and contraction due to extreme heat.

3. Left Side: 
   NOTE:

   Initial torque of all the bolts are 16 N.m (12 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.

   • Install a new EGR cooler intake pipe gasket onto the exhaust manifold.
   • Align the exhaust manifold to the EGR cooler intake pipe.
   • Install the non-coated standard stud bolts with coated washers into position #4.
   • Install the coated stud bolts with coated washers into position #5.
   • Install a coated bolt with a coated washer in position #1.
   • Install a coated bolt only in position #2.
   • Install a non-coated standard bolt with a coated washer in position #3.
   Fig 3: Exhaust Manifold Stud Bolt & Washer Locations

   Courtesy of CHRYSLER GROUP, LLC
4. Torque the bolts to specifications in sequential order:

   Location	N.m	Ft. Lbs.
   1	19	14
   2, 3, 4	25	18
   5, 6	16	12
   7, 8,	25	18
   9	16	12
   10	25	18

5. Install the oil indicator tube.
6. Connect the knock sensor electrical connector.
7. Install the heat shield. Refer to SPECIFICATIONS  .
   Fig 4: Locating Exhaust Manifold Bolts & Washers Placement Locations

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   A special coating is used on the bolts and washers for extreme heat. Placement of the bolts and washers are crucial for expansion and contraction due to extreme heat.

8. Right Side: 
   NOTE:

   Initial torque of all the bolts are 16 N.m (12 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.

   • Install a new EGR cooler intake pipe gasket onto the exhaust manifold.
   • Align the exhaust manifold to the EGR cooler intake pipe.
   • Install the non-coated standard stud bolts with coated washers into position #4.
   • Install the coated stud bolts with coated washers into position #5.
   • Install a coated bolt with a coated washer in position #1.
   • Install a coated bolt only in position #2.
   • Install a non-coated standard bolt with a coated washer in position #3.
   Fig 5: Exhaust Manifold Stud Bolt Locations

   Courtesy of CHRYSLER GROUP, LLC
9. Torque the bolts to specifications in sequential order: :

   Location	N.m	Ft. Lbs.
   1	19	14
   2, 3, 4	25	18
   5, 6	16	12
   7, 8,	25	18
   9	16	12
   10	25	18

10. Install the heat shield. Refer to SPECIFICATIONS  .
11. Install the inner wheel well splash shield.
12. Install the front wheels.
    CAUTION:

    Do not damage engine harness while lowering the engine.

    Fig 6: Engine Mount & Bolt

    Courtesy of CHRYSLER GROUP, LLC
13. Lower the engine onto the frame and remove the jack stand.
14. Raise the vehicle.

    Right side shown in illustration, left side similar. 

15. Install the right and left engine mount through bolts (3) and tighten to 100 N.m (74 ft. lbs.).
    Fig 7: Retaining Bolts & Nuts

    Courtesy of CHRYSLER GROUP, LLC
16. Install the right (2) and left (1) exhaust pipe/catalytic converter assembly. Tighten the bolts to 100 N.m (74 ft. lbs.).
    Fig 8: Oxygen Sensors & Electrical Connectors

    Courtesy of CHRYSLER GROUP, LLC
17. Connect the oxygen sensor electrical connectors (1).
    Fig 9: Remove/Install Intake Tube

    Courtesy of CHRYSLER GROUP, LLC
18. Install the EGR intake tube nuts (2). Tighten the to 23 N.m (17 ft. lbs.).
19. Lower the vehicle.
20. Install the engine cover (1).
21. Connect the negative battery cable (1).
22. Start the engine and check for leaks.