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Manifold, Exhaust: Installation: Installation

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Fig 1: Upstream And Downstream Oxygen Sensors, Maniverter & Fasteners
GC0152389Courtesy of CHRYSLER GROUP, LLC
  1. If removed, install the upstream (2) and downstream (3) oxygen sensor(s) to the maniverter. Refer to SENSOR, OXYGEN, INSTALLATION .
  2. Clean the mating surfaces of the cylinder head and the maniverter flange.
  3. Install a new maniverter gasket on the cylinder head.
    CAUTION:

    The maniverter studs are installed in the cylinder head with a thread sealant. If the studs rotate during service this indicates that the seal is broken and the stud must be replaced. Failure to replace the studs can result in engine oil leaking onto the exhaust manifold.

  4. Mark the end of the nine maniverter mounting studs with a paint pen or equivalent to indicate possible stud rotation.
  5. Guide the maniverter (4) into place onto the studs. Install and tighten the nine nuts (1) to 20 N.m (15 ft. lbs.).
  6. Check the markings on the studs for indication of rotation. If there is evidence of stud rotation, replace the stud. Refer to MANIFOLD, EXHAUST, STANDARD PROCEDURE .
  7. Engage the wire harness retainers and connect the upstream (2) and downstream (3) oxygen sensor electrical connectors.
    Fig 2: Maniverter Heat Shield & Fasteners
    GC0152388Courtesy of CHRYSLER GROUP, LLC
  8. Install the maniverter heat shield (2) with four bolts (3) and two nuts (1). Tighten the nuts (1) and bolts (3) to 9 N.m (80 in. lbs.).
    Fig 3: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  9. Raise and support the vehicle. Refer to HOISTING .
  10. Install the muffler flexible intake pipe to the maniverter flange with two nuts (1). Tighten the nuts (1) to 25 N.m (18 ft. lbs.).
  11. Install the maniverter pipe extension support to the oil pan. Tighten the bolt (2) to 50 N.m (37 ft. lbs.).
    Fig 4: Front Cooling Module Assembly & Fasteners
    GC0153119Courtesy of CHRYSLER GROUP, LLC
  12. Install the front cooling module assembly (4) with four bolts (1), eight bolts and washers (2) and eight bolts and washers (3). Tighten the eight bolts (2) to 45 N.m (33 ft. lb.). Tighten the four bolts (1) to 24 N.m (18 ft. lb.). Tighten the eight bolts (3) to 45 N.m (33 ft. lb.).
    Fig 5: Wire Harness Retainer
    GC0103128Courtesy of CHRYSLER GROUP, LLC
  13. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.
    Fig 6: Wire Harness Push Pin
    GC0103127Courtesy of CHRYSLER GROUP, LLC
  14. Engage the wire harness connector (1) to the bumper reinforcement.
    Fig 7: Horn, Connector & Fasteners
    GC0084012Courtesy of CHRYSLER GROUP, LLC
  15. Connect the harness connector (2) to the horn (1).
    Fig 8: Removing/Installing Front Impact Sensor
    GC0084280Courtesy of CHRYSLER GROUP, LLC
  16. Connect the harness connector (1) to the right and left front impact sensors (3). Refer to SENSOR, IMPACT, INSTALLATION .
    Fig 9: Latch Cable
    GC0084616Courtesy of CHRYSLER GROUP, LLC
  17. Press down the latch release (3) and install the hood latch cable (2) to the latch.
    Fig 10: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  18. Engage the A/C liquid line (1) to the A/C discharge line (2) and connect the lines to the A/C condenser tapping block (3) using new dual plain seals lubricated with clean refrigerant oil. Install the retaining bolt (4) and tighten to 14 N.m (10 ft. lbs.).
    Fig 11: Engine Cooling Fan, Connector & Fasteners
    GC0152367Courtesy of CHRYSLER GROUP, LLC
  19. Connect the lower coolant hose to the radiator.
  20. Connect the cooling fan harness connector (3).
    Fig 12: Cooling Fan Resistor & Fan Assembly
    GC0152401Courtesy of CHRYSLER GROUP, LLC
  21. Connect the upper coolant hose to the radiator.
  22. Connect the harness connector to the cooling fan resistor (1).
  23. Install the right and left headlamp units.
  24. Install the front fascia. Refer to FASCIA, FRONT, INSTALLATION .
  25. Install both front inner wheel well splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .
  26. Install both front tire and wheel assemblies. Refer to INSTALLATION .
    Fig 13: Tunnel Support Brace & Bolts
    GC0152449Courtesy of CHRYSLER GROUP, LLC
  27. Remove the four bolts (1) and install the tunnel support brace (2). Reinstall the four bolts (1) and tighten to 90 N.m (60 ft. lb.).
    Fig 14: Lower Air Dam/Belly Pan
    GC0082359Courtesy of CHRYSLER GROUP, LLC
  28. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
    Fig 15: Air Cleaner Body Assembly
    GC0152416Courtesy of CHRYSLER GROUP, LLC
  29. Lower the vehicle.
  30. Install the air cleaner body (6). Refer to BODY, AIR CLEANER, INSTALLATION .
    Fig 16: Engine Cover
    GC0152354Courtesy of CHRYSLER GROUP, LLC
  31. Fill the cooling system. Refer to STANDARD PROCEDURE .
  32. Connect the negative battery cable. Tighten nut to 5 N.m (45 in. lb.).
  33. Evacuate and charge the refrigerant system. Refer to STANDARD PROCEDURE .
  34. Install the engine cover (1).
  35. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
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