Exhaust Manifold Replacement (6-Cylinder) - Jeep 1979 CJ-5 Technical & Service Manual

1K-6
EXHAUST SYSTEMS
EXHAUST MANIFOLD
Replacement—Six-Cylinder Engine
Removal
The intake and exhaust manifolds are attached as a
unit to the cylinder head on the left side of the engine. A
gasket is used between the intake manifold and the
cylinder head. None is used between the exhaust mani-
fold and cylinder head. An asbestos gasket is used at the
mating surfaces of the intake manifold to exhaust mani-
fold and also between the exhaust manifold and exhaust
pipe (fig. 1K-7).
Fig. 1K-7 Manifold Assembly
N O T E : It is necessary to remove intake and exhaust
manifold assembly from the engine before separating
the manifolds.
(1) -Remove air cleaner.
(2) Disconnect choke heater tube from choke coil
housing. Disconnect clean air tube from carburetor.
(3) Disconnect accelerator cable from carburetor.
(4) Remove carburetor from intake manifold and
set aside with vacuum lines attached. It is necessary to
disconnect only fuel line and canister line.
(5) Disconnect hose at EGR valve.
(6) Disconnect accelerator cable from accelerator
bellcrank.
(7) Disconnect PCV vacuum hose from intake
manifold.
(8) Remove spark CTO vacuum tubes and dis-
connect TCS solenoid vacuum valve wiring, if equipped.
(9) Disconnect Air Guard hoses at air pump and air
injection manifold check valve. Disconnect diverter vac-
uum hose from manifold and remove diverter valve with
hoses.
(10) Remove air pump/power steering mounting
bracket, if equipped.
(11) Remove air pump.
(12) Detach power steering pump and set aside, if
equipped. Do not remove hoses.
(13) Remove air conditioning drive belt idler assem-
bly from cylinder head, if equipped.
(14) Disconnect exhaust pipe from manifold flange.
(15) Remove manifold attaching screws, nuts and
clamps. Remove intake and exhaust manifold as an as-
sembly. Discard gasket.
(16) Remove accelerator control bracket.
(17) Separate manifolds.
(18) Remove distributor CTO tube clamp and install
on replacement manifold.
(19) Remove air injection manifold and screws and
install on replacement manifold.
Installation
(1) Install replacement gasket between manifolds.
Install accelerator control bracket. Tighten nuts finger
tight.
CAUTION: Manifolds must be held together loosely
enough to slide when manifolds are attached to cylinder
head.
(2) Install choke clean air tube into bottom of ex-
haust manifold and install tube clip.
(3) Position replacement intake manifold gasket on
cylinder head and install manifold assembly. Tighten
manifold attaching bolts and nuts in sequence (fig. 1K-8)
to 23 foot-pounds (31 N»m) torque.
(4) Install flange gasket and connect exhaust pipe to
manifold flange. Use replacement nuts.
(5) Install carburetor to intake manifold. Connect
fuel line and hose from vapor canister.
(6)* Install air conditioning idler assembly, if
removed.
(7) Install air pump, if removed.
(8) Install air pump/power steering pump mount-
ing bracket, if removed.
^ (9) Install diverter valve. Connect hoses to air pump
and checWalve. Connect vacuum hose to manifold.
(10) Install drive belts and tighten to specification.
Refer to Chapter 1C—Cooling Systems.
(11) Install spark CTO vacuum tubes. Connect TCS
wiring, if removed.
(12) Connect vacuum line at EGR valve.