:	Jun 21, 2004

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Disconnect the battery ground cable.

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Remove the engine cover.

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Release the battery positive cable.   Loosen the clamp.   Release the grommet.

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Release the wiring harness clip.   Remove the bolt.

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: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.

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Remove the engine undershield.

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Release the exhaust system from the exhaust manifold.   Remove and discard the 2 bolts.

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Lower the vehicle.

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: Protect the engine during this operation. Raise the engine clear of its LH mount.   Remove the nut.

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: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination. Remove the EGR pipe.   Release the 2 union nuts.

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Disconnect the high tension (HT) electrical connectors.   Move the leads aside for access.

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: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination. Remove the dipstick tube.   Remove the dipstick.   Remove the bolt.   Discard the O-ring seal.

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Remove the exhaust manifold.   Remove the 6 nuts.   Remove and discard the gasket.

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:   The exhaust manifold gasket connecting links must be positioned to the lower edge of the manifold. Install the exhaust manifold.   Install a new gasket.   Clean the component mating faces.   Tighten the nuts evenly in the sequence shown to 25 Nm (18 lb.ft).

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Install the dipstick tube.   Clean the component mating faces.   Install a new O-ring seal.   Lubricate the seal with clean engine oil.   Tighten the bolt to 10 Nm (7 lb.ft).   Install the dipstick.

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Connect the HT electrical connectors.

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Install the EGR pipe.   Clean the component mating faces.   Initially, finger tighten the nuts.   Finally, tighten the nuts to 40 Nm (30 lb.ft).

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Lower the engine onto its mount.   Tighten the nut to 90 Nm (66 lb.ft).

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Raise the vehicle.

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Install the exhaust system.   Clean the component mating faces.   Install new bolts and tighten to 40 Nm (30 lb.ft).

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Install the engine undershield.

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Lower the vehicle.

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:   Apply petroleum jelly to the battery terminals. Connect the battery positive cable.   Clean the component mating faces.   Install the grommet.   Tighten the clamp nut to 10 Nm (7 lb.ft).

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Secure the wiring harness clip.   Tighten the bolt to 10 Nm (7 lb.ft).

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Install the engine cover.

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Connect the battery ground cable.