Exhaust Manifold LH

Exhaust Manifold LH-5.4L





Special Tool(s)

Removal

All vehicles

1. CAUTION: The air suspension switch must be turned off prior to raising the vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which could result in shifting of the vehicle during the repair operation.

If equipped, turn the air suspension switch off.
2. Disconnect the battery ground cable.
3. Remove the air cleaner outlet pipe.
4. Partially drain the engine cooling system.





5. Remove the upper air deflector.
1 Remove the pin-type retainers.
2 Remove the upper air deflector.





6. Disconnect the throttle body cam.
1 Disconnect the accelerator cable.
2 Disconnect the speed control actuator cable.
3 Remove the accelerator return spring.





7. Position the heated Positive Crankcase Ventilation (PCV) hose harness aside.
^ Disconnect the PCV hose from the throttle body adapter.
^ Disconnect the heated throttle body outlet hose from the throttle body adapter.
^ Disconnect the PCV hose from the intake manifold.
^ Remove the PCV valve and position the harness aside.





8. Disconnect the heated throttle body inlet hose from the throttle body adapter.





9. Disconnect the evaporative emission canister purge valve hose.





10. Disconnect the main vacuum harness from the throttle body adapter.





11. Remove the Idle Air Control (IAC) valve fresh air tube.





12. Disconnect the IAC electrical connector.





13. Disconnect the EGR valve vacuum hose.





14. Disconnect the Throttle Position (TP) sensor electrical connector, and the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid electrical and vacuum connectors.





15. Disconnect the differential pressure feedback EGR system electrical connector.





16. Remove the bolt and disconnect the brake booster vacuum tube. Position the bracket and tube aside.





17. Remove the exhaust manifold to EGR valve tube.
^ Disconnect the upper fitting.
^ Disconnect the two differential pressure feedback EGR system hoses.
^ Disconnect the lower fitting and remove the tube.





18. Remove the differential pressure feedback EGR system bracket bolt.





19. Remove the four bolts and remove the throttle body adapter.
^ Discard the throttle body adapter gasket.





20. Rotate the belt tensioner clockwise and detach the drive belt from the generator pulley.





21. Disconnect the generator upper mounting bracket.
^ Disconnect the harness routing clip.
^ Remove the two bolts.





22. Remove the generator lower mounting bolts and position the generator aside.





23. Install the special tool.





24. Remove the fan shroud mounting bolts.
25. Remove the LH front wheel and tire.
26. Remove the front fender splash shield.





4x4 vehicles
27. Remove the fasteners and the engine skid shield.





28. Remove the six bolts and the transmission skid shield.

All vehicles
29. Remove the dual converter Y-pipe.





30. NOTE: The caged nut on the frame may break during bolt removal. If necessary, install a new nut.

Remove the LH engine mount bolt.





31. Remove the RH engine mount nut.





32. Loosen the rear transmission mount nuts.





33. Index-mark the driveshaft flange yoke and the pinion flange.





34. Remove the four bolts.





35. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.

Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange.





36. CAUTION: The driveshaft alignment bushing can be damaged if the driveshaft is allowed to hang unsupported.

Wire the driveshaft to the frame crossmember to support it at the same height as when it was installed.
37. Lower the vehicle.





38. Install the special tool and raise the engine.
39. Raise and support the vehicle.





40. Remove the bolts and the heat shield.





41. Remove the eight nuts, the exhaust manifold and the gaskets.
^ Discard the exhaust manifold gaskets.

42. Clean and inspect the exhaust manifold.

Installation





All vehicles
1. Position the exhaust manifold gaskets and the exhaust manifold. Loosely install the nuts.





2. Tighten the nuts in the sequence shown.





3. Install the heat shield and bolts.
4. Lower the vehicle.





5. NOTE: Make sure the engine mounts align with, and settle into, the frame brackets as the engine is lowered.

Lower the engine and remove the special tool.
6. Raise and support the vehicle.





7. Remove the driveshaft support wire.





8. Align the index marks and install the driveshaft flange yoke to the pinion flange. Tighten the bolts in the sequence shown.





9. Tighten the rear transmission mount nuts.





10. Install the RH engine mount nut.





11. Install the LH engine mount bolt.
12. Install the dual converter Y-pipe.





4x4 vehicles
13. Position the transmission skid shield and install the six bolts.





14. Position the engine skid shield and install the fasteners.

All vehicles
15. Install the front fender splash shield.
16. Install the LH front wheel and tire.





17. Position the fan shroud and install the mounting bolts.





18. Remove the special tool.





19. Position the generator and install the lower mounting bolts.





20. Install the generator upper mounting bracket bolts and harness routing clip.





21. Rotate the belt tensioner clockwise and install the drive belt. Refer to the decal on the radiator upper air deflector for belt routing.





22. Install a new intake manifold-to-throttle body adapter gasket.





23. Install the throttle body adapter and the four bolts.





24. Install the differential pressure feedback EGR system bracket bolt.





25. Install the exhaust manifold to EGR valve tube.
^ Position the tube and hand-tighten the fittings.
^ Tighten the upper fitting.
^ Tighten the lower fitting.
^ Connect the two differential pressure feedback EGR system hoses.





26. Connect the brake booster vacuum tube and position the bracket. Install the bolt.





27. Connect the differential pressure feedback EGR system electrical connector.





28. Connect the TP sensor electrical connector, and the EGR vacuum regulator solenoid electrical and vacuum connectors.





29. Connect the EGR valve vacuum hose.





30. Connect the IAC electrical connector.





31. Install the IAC fresh air tube.





32. Connect the main vacuum harness.





33. Connect the evaporative emission canister purge valve hose.





34. Connect the heated throttle body inlet hose to the throttle body adapter.





35. Install the heated PCV hose harness.
^ Install the PCV valve.
^ Connect the PCV hose to the intake manifold.
^ Connect the heated throttle body outlet hose.
^ Connect the PCV hose to the throttle body adapter.





36. Connect the throttle body cam.
1 Connect the accelerator cable.
2 Connect the speed control actuator cable.
3 Install the throttle return spring.





37. Install the upper air deflector.
1 Position the upper air deflector.
2 Install the pin-type retainers.
38. Install the air cleaner outlet pipe.
39. Connect the battery ground cable.
40. Fill and bleed the engine cooling system.
41. If equipped, turn on the air suspension switch.