Removing
All cars
1. Disconnect a wire of weight from the storage battery. For more information, refer to Specification
2. Remove the engine cover. For more information refer to Engine Cover - 4.0L (12.30.50)
Right hand drive vehicles
3. Disconnect the positive cable from the battery.
- Release the clamp.
- Release the sleeve.
Right hand drive vehicles
4. Release the cable harness clamp. Turn out a bolt.
All cars
5.
WARNING: Do not work on or under a vehicle that is only supported by a jack. Always place secure supports under the vehicle.
Raise and support the vehicle.
6. Remove the motor shield. For more information refer to Motor Protection (76.10.50)
7. Disconnect the exhaust system from the exhaust manifold. Loosen and discard 2 bolts.
8. Lower the car.
9.
WARNING: When performing this operation, it is necessary to protect the motor.
Raise the engine from the left support. Loosen the nut.
10.
CAUTION: Before disconnecting or removing parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
Remove the EGR pipeline. Loosen 2 union nuts.
11. Disconnect high voltage electrical connectors (HT). Move the wires aside to gain access.
12.
CAUTION: Before disconnecting or removing parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
Remove the dipstick tube.
- Remove the level dipstick.
- Turn out a bolt.
- Discard the O-ring.
13. Remove the exhaust manifold.
- Remove 6 nuts.
- Remove the gasket and discard it.
Installation
All cars
1.
NOTE: The exhaust manifold gasket tie rods must be located at the lower edge of the manifold.
Install the exhaust manifold.
- Install a new gasket.
- Clean the contact surfaces of the parts.
- Tighten the nuts evenly in the sequence shown (tightening torque 25 Nm).
2. Install the dipstick tube.
- Clean the contact surfaces of the parts.
- Install a new sealing ring.
- Lubricate the seal with clean engine oil.
- tighten bolt (tightening torque 10 Nm).
- Insert the level probe.
4. Install the EGR pipeline.
- Clean the contact surfaces of the parts.
- Tighten the nuts by hand first.
- Finally tighten the nuts with a torque of 40 Nm.
6. Raise the car.
7. Install the exhaust system.
- Clean the contact surfaces of the parts.
- Install new bolts and tighten them (tightening torque 40 Nm).
9. Lower the car.
Right hand drive vehicles
10.
NOTE: Apply petroleum jelly to the battery terminals.
Connect the positive battery cable.
- Clean the contact surfaces of the parts.
- Install the sealing sleeve.
- Tighten clamp nut (tightening torque 10 Nm).
11. Attach the cable harness clamp. tighten bolt (tightening torque 10 Nm).
All cars
12. Install the engine cover. For more information refer to Engine Cover - 4.0L (12.30.50)
13. Connect the ground wire to the battery. For more information, refer to Specification
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