REMOVAL & INSTALLATION
See Figures 1 through 8
If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.
- Have the A/C system recovered by a MVAC-trained, EPA-certified, automotive technician.
- Disconnect the battery cables, negative cable first.
- Remove the air inlet tube.
- Drain and recycle the engine coolant.
- Remove the cooling fan and shroud.
- Relieve the fuel system pressure, as outlined in Fuel System .
- Disconnect the fuel lines; refer to Fuel System .
- Remove the upper radiator hose.
- Remove the wiper module and support bracket.
- Disconnect and plug the compressor outlet hose at the compressor and remove the bolt retaining the hose assembly to the right coil bracket. Cap the compressor opening.
- Remove the engine harness connector from the retaining bracket on the brake vacuum booster. Detach the connector.
- Disconnect the throttle valve cable from the throttle body.
- Disconnect the heater outlet hose.
- Remove the nut retaining the ground strap to the right cylinder head.
- Remove the upper stud and lower bolt retaining the heater outlet hose to the right cylinder head and position out of the way.
- Remove the blower motor resistor and remove the bolt retaining the right engine mount to the lower engine bracket.
- Disconnect both oxygen sensor electrical connectors.
- Raise and safely support the vehicle.
- Remove the engine mount through bolts.
- Remove the EGR tube line nut from the right exhaust manifold.
- Disconnect the exhaust pipes from the manifolds.
- Lower the exhaust system and hang it from the crossmember with wire.
- To remove the left exhaust manifold, remove the engine mount from the engine block and remove the 8 bolts retaining the exhaust manifold.
- Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 in. (100mm).
- Remove the 8 bolts retaining the right exhaust manifold and remove the manifold.
- If the exhaust manifolds are being replaced, transfer the oxygen sensors and tighten to 27-33 ft. lbs. (37-45 Nm). On the right manifold, transfer the EGR tube connector and tighten to 33-48 ft. lbs. (45-65 Nm).
- Clean the mating surfaces of the exhaust manifolds and cylinder heads.
- Position the exhaust manifolds to the cylinder heads and install the retaining bolts. Tighten, in the sequence shown, to 15-22 ft. lbs. (20-30 Nm).
- Position and connect the EGR valve and tube assembly to the exhaust manifold. Tighten the line nut to 26-33 ft. lbs. (35-45 Nm).
- Install the left engine mount and tighten the bolts to 15-22 ft. lbs. (20-30 Nm). Lower the engine onto the mounts and remove the jack. Install the engine mount through bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
- Cut the wire and position the exhaust system. Tighten the nuts to 20-30 ft. lbs. (27-41 Nm).
Make sure the exhaust system clears the No. 3 crossmember. Adjust as necessary.
- Lower the vehicle. Connect both oxygen sensors and install the bolt retaining the right engine mount to the frame. Tighten to 15-22 ft. lbs. (20-30 Nm).
- Install the blower motor resistor. Position the heater outlet hoses. Install the upper stud and lower bolt and tighten to 15-22 ft. lbs. (20-30 Nm). Install the ground strap onto the stud and tighten the nut to 15-22 ft. lbs. (20-30 Nm).
- Connect the heater outlet hose. Connect and if necessary, adjust the throttle valve cable.
- Attach the engine connector and transmission harness connector. Install the connector to the retaining bracket on the brake vacuum booster.
- Connect the air conditioning compressor outlet hose to the compressor and install the bolt retaining the hose assembly to the right coil bracket.
- Install the upper radiator hose and connect the fuel lines. Install the wiper module and retaining bracket.
- Install the cooling fan and shroud. Fill the cooling system.
- Install the air inlet tube. Connect the battery cables, start the engine and check for leaks.
- Have a MVAC-trained, EPA-certified, automotive technician evacuate and recharge the air conditioning system.
5.0L and 5.8L Engines
See Figures 9 and 10
- Disconnect the negative battery cable.
- Remove the thermactor hardware from the right exhaust manifold. Remove the air cleaner and inlet duct, if necessary.
- Tag and disconnect the spark plug wires. Remove the spark plugs.
- Disconnect the engine oil dipstick tube from the exhaust manifold stud.
- Raise and safely support the vehicle. Disconnect the exhaust pipes from the exhaust manifolds.
- Remove the engine oil dipstick tube by carefully tapping upward on the tube. Detach the oxygen sensor connector.
- Lower the vehicle.
- Remove the attaching bolts and washers and remove the exhaust manifolds.
- Clean the manifold, cylinder head and exhaust pipe mating surfaces.
- Position the manifolds on the cylinder heads and install the mounting bolts and washers. Working from the center to the ends, tighten the bolts to 18-24 ft. lbs. (24-32 Nm).
- Install the engine oil dipstick tube. Attach the oxygen sensor connector.
- Install the spark plugs and connect the spark plug wires.
- Install the thermactor hardware to the right exhaust manifold. Install the air cleaner and inlet duct, if removed.
- Raise and safely support the vehicle. Position the exhaust pipes to the manifolds. Alternately tighten the exhaust pipe flange nuts to 20-30 ft. lbs. (27-41 Nm).
- Lower the vehicle, start the engine and check for exhaust leaks.