Installation - Medium 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.
   Fig 2: Exhaust Manifold Stud Bolt & Washer Locations

   Courtesy of CHRYSLER GROUP, LLC
3. Left Side: 
   • Install a new EGR cooler intake pipe gasket onto the exhaust manifold.
   • Align the exhaust manifold to the EGR cooler intake pipe.
   • Using the sequence shown in illustration, Install the exhaust manifold retaining bolts and pre-tighten to 16 N.m (12 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.
   • Install the oil indicator tube.
   • Connect the knock sensor electrical connector.
4. Re-check the torque at 30 N.m (22 ft. lbs.) using the sequence shown in illustration.
5. Install the heat shield. Refer to SPECIFICATIONS  .
   NOTE:

   The bolts used to secure the exhaust manifold are stainless steel at locations 7 and 8. All bolts removed must be installed in the same location were they were removed from.

   Fig 3: Exhaust Manifold Stud Bolt Locations

   Courtesy of CHRYSLER GROUP, LLC
6. Right Side:  Using the sequence shown in illustration, install the exhaust manifold retaining bolts and tighten to 16 N.m (12 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.
7. Re-check the torque at 25 N.m (18 ft. lbs.) using the sequence shown in illustration.
8. Install the heat shield. Refer to SPECIFICATIONS  .
9. Install the inner wheel well splash shield.
10. Install the front wheels.
    CAUTION:

    Do not damage engine harness while lowering the engine.

    Fig 4: Engine Mount & Bolt

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

    Right side shown in illustration, left side similar. 

13. Install the right and left engine mount through bolts (3) and tighten to 100 N.m (74 ft. lbs.).
    Fig 5: Retaining Bolts & Nuts

    Courtesy of CHRYSLER GROUP, LLC
14. Install the right (2) and left (1) exhaust pipe/catalytic converter assembly. Tighten the bolts to 100 N.m (74 ft. lbs.).
    Fig 6: Oxygen Sensors & Electrical Connectors

    Courtesy of CHRYSLER GROUP, LLC
15. Connect the oxygen sensor electrical connectors (1).
    Fig 7: Remove/Install Intake Tube

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