Comanche 2WD L4-150 2.5L VIN E TBI (1989)
16.
Drain the cooling system and remove the heater hoses from the intake manifold.
17.
Remove and discard bolts # 2, # 3, # 4 and # 5 securing the intake manifold to the cylinder head (Figure 2). Slightly loosen bolt # 1 and nuts
# 6 and # 7.
18.
Remove the intake manifold and gasket. Drain the coolant from the manifold.
19.
Disconnect the exhaust downpipe from the exhaust manifold.
20.
Remove and discard bolt # 1 and nuts # 6 and # 7.
21.
Remove the exhaust manifold.
Exhaust Manifold/Oxygen Sensor - Installation
C.
INSTALL EXHAUST MANIFOLD AND OXYGEN SENSOR:
1.
Install the oxygen sensor from the emissions service package into the new exhaust manifold. Tighten to 22 ft-lbs (30 Nm).
2.
Transfer the EGR tube to the new manifold using the supplied bolts and gasket. Tighten the bolts to 14 ft-lbs (19 Nm).
3.
If the exhaust manifold studs are broken, replace them with the studs supplied in the manifold package.
4.
Install the supplied spacers on the exhaust manifold studs # 6 and # 7 (Figure 3).
5.
Install the exhaust manifold on the studs. The exhaust manifold must be centrally located over the studs and spacers. Loosely install the
provided bolt # 1 and nuts with washers for studs # 6 and # 7 (Figure 3).
6.
Clean the old intake manifold gasket material from the intake manifold and cylinder head. Then install the provided intake manifold gasket
over the alignment dowels on the cylinder head.
7.
Install the intake manifold and loosely install the provided bolts and washers for bolt locations # 2, # 3, # 4 and # 5 (Figure 3).
8.
Tighten bolt # 1 to 30 ft-lbs (41 Nm).
9.
Tighten bolts in the following torque sequence; # 2, # 3, # 4 and then # 5 to 23 ft-lbs (31 Nm).
10.
Tighten nuts # 6 and # 7 to 23 ft-lbs (31 Nm).
11.
Tighten the EGR tube intake manifold nut to 30 ft-lbs (41 Nm).
12.
Connect the four vacuum hoses to the throttle body (Figure 1).
13.
Connect all vacuum hoses (MAP sensor, EGR, air cleaner, brake booster) to the vacuum tube assembly (Figure 1)
14.
Install the CCV hose at the rear of the cylinder head cover.
