B
118
Repair and Service Manual
ENGINE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
668061
Tool List Qty.
Spring Hook.................................................................1
Ratchet ........................................................................ 1
Socket, 19mm.............................................................. 1
Socket, 14mm.............................................................. 1
Wrench, 19mm ............................................................ 1
Wrench, 17mm ............................................................ 1
Wrench, 14mm ............................................................ 1
Torque Wrench, ft. lbs.................................................. 1
The normal operating temperature
of the exhaust system is very high.
Never work around or attempt to
service any part of the exhaust system until it has
cooled.
NOTICE: Hardware that is removed must always be
installed in their original positions unless otherwise
specified. Non specified torque figures are as
shown in the table contained in GENERAL INFOR-
MATION & ROUTINE MAINTENANCE Section.
1. Remove the truck bed from the vehicle. See TRUCK
BED REMOVAL on page 46.
2. Remove the three springs (13) that secure the
exhaust pipe (14) to the exhaust manifold (2) (Ref.
Fig. 15).
3. Remove the three springs (13) that secure the muf-
fler (1) to the exhaust pipe (14).
4. Remove the nut (21) that secure the J-hook (20) to
the frame. Rotate the J-hook out of the isolator
hangers (3).
5. Remove the nuts (12) and bolts (25) that secure the
muffler support bracket (19) to the frame.
6. Remove the exhaust pipe (14).
7. Disconnect the oxygen sensor (9).
8. Remove the bolt (24) that secures the exhaust mani-
fold (2) to the manifold bracket (18).
9. Remove the bolts (6) that secure the exhaust mani-
fold (2) to the engine. Remove the manifold and gas-
kets (7) from the engine.
NOTICE: When replacing the exhaust manifold (2),
new exhaust gaskets (7) must be used.
10. Install new exhaust manifold gaskets (7) onto the
engine studs.
11. Place the exhaust manifold onto the engine studs.
Secure the manifold to the engine with nuts (6).
NOTICE: The exhaust manifold nuts (6) must be
torqued in three stages in a cross-pattern sequence
(See Fig. 16).
Fig. 16 Exhaust Manifold Installation
12. Install the exhaust pipe and muffler in the reverse
order of removal. Use new gasket (15). Tighten the
hardware to the torque values specified.
Item Torque Specification
21 22 - 26 in. lbs. (30 - 35 Nm)
25, 12 16 - 18 in. lbs. (22 - 25 Nm)
24 13 - 16 ft. lbs. (18 - 22 Nm)
9 15 - 22 ft. lbs. (20 - 30 Nm)
1
2
3
4
57
8
Driver
Side
Passenger
Side
6
Exhaust Manifold Torque sequence:
1st: 6 ft. lbs. (8 Nm)
2nd: 12 ft. lbs. (16.5 Nm)
3rd: 18 ft. lbs. (24.5 Nm)
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