Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the right oxygen sensor connector from the bracket on the coolant pipe and disconnect the connector.
3. Remove the bolt securing the upper right engine crossmember to the upper bracket.
4. Loosen the bolt securing the upper right engine crossmember to the body and move the crossmember away from the upper bracket.
5. Raise the car on a lift.
6. Remove the lower engine guard.
EXTERIOR PARTS, REPAIR WORK, Lower engine protection shield.
7. Remove the exhaust pipe.
COLLECTORS AND EXHAUST SYSTEM: MOD. K, V6 engine, REPAIR WORK, Downpipe: except for North American market countries.
8. Unscrew the bolt securing the lower cross member to the bracket on the pallet.
9. Loosen the bolt securing the lower engine crossmember to the subframe and move the crossmember away from the bracket on the pan.
10. Release the gear selection cable from the mounting on the body.
11. Unscrew the 2 bolts securing the transfer case heat shield to the lower engine crossmember bracket.
12. Loosen the nut securing the heat shield to the rear axle drive shaft housing.
13. Loosen the nut securing the heat shield to the transfer case housing.
14. Unscrew the 4 nuts securing the right exhaust manifold to the cylinder head.
15. Remove the exhaust manifold and discard its gaskets.
Installation
1. Wipe the exhaust manifold and the mating surface on the cylinder head.
2. After installing the new gasket, install the exhaust manifold, tighten the nuts and tighten them to 45 Nm.
3. Install the heat shield on the transfer case.
4. Fit the heat shield mounting nut to the transfer case housing and tighten it to a torque of 45 Nm.
5. Fit the heat shield mounting nut to the transfer case drive gear housing and tighten it to a torque of 25 Nm.
6. Screw in 2 bolts securing the heat shield to the lower engine crossmember bracket and tighten them to a torque of 9 Nm.
7. Secure the gear selection cable to the body.
8. Install the lower cross member on the tray bracket, screw in the bolts and tighten them to a torque of 100 Nm.
9. Tighten the lower cross member mounting bolt to the subframe to a torque of 100 Nm.
10. Install the exhaust pipe.
COLLECTORS AND EXHAUST SYSTEM: MOD. K, V6 engine, REPAIR WORK, Downpipe: except for North American market countries.
11. Reinstall the lower engine guard.
EXTERIOR PARTS, REPAIR WORK, Lower engine protection shield.
12. Lower the car lift.
13. Connect the right oxygen sensor connector, secure the connector to the cooling system pipe bracket.
14. Install the upper right cross member on the bracket, screw in the bolt and tighten it to a torque of 100 Nm.
15. Tighten the upper cross member mounting bolt to the body to a torque of 100 Nm.
16. Connect the negative battery terminal.
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