2012 Jeep Wrangler JK Factory Service Manual 09 - Engine, 2.8L Diesel

MANIFOLD, Exhaust

REMOVAL

REMOVAL

  1. Disconnect the negative battery cable.

    2.  
  2. Remove the air cleaner body (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner - Removal) .

    3.  
  3. Disconnect the crankcase vent hose (1) from the oil separator (2).

    4.  
  4. Remove the air cleaner outlet tube.

    5.  
  5. Remove the air cleaner outlet tube from turbocharger inlet elbow.

    6.  
  6. Remove the turbo charger outlet hose from CAC inlet.

    7.  
  7. If equipped, remove the lower transmission fill tube bolt (1).

    8.  
  8. If equipped, remove the bolt (1) and the transmission fill tube (2).

    9.  
  9. Remove the catalytic converter (Refer to 11 - Exhaust System/CONVERTER, Catalytic - Removal) .

    10.  
  10. Remove the bolts (1) from the turbocharger to engine support bracket and remove the bracket.

    11.  
  11. Remove the bolts (1) and exhaust manifold heat shield (2).

    12.  
  12. Remove the turbocharger oil feed line.

    13.  
  13. Remove the bolt (1) and turbocharger oil return line (2).

    14.  
  14. Disconnect the turbocharger module connector (1).

    NOTE:

    Turbocharger removed for clarity.


    15.  
  15. Remove the nuts and the exhaust manifold and turbocharger as an assembly.

    16.  
  16. If necessary, remove the turbocharger from exhaust manifold.

    17.  

INSTALLATION

INSTALLATION

Special Tools: Click to display a list of tools used in this procedure

  1. Clean and inspect the gasket surface of the exhaust manifold and cylinder head.

    2.  
  2. If necessary, clean and inspect the gasket surface of the exhaust manifold and turbocharger.

    3.  
  3. If necessary, using a new gasket install the turbocharger to the exhaust manifold. Tighten nuts to 32 N·m (23 ft. lbs.).

    4.  
  4. Install a new exhaust manifold gasket.

    5.  
  5. Install the Tool, Exhaust Manifold Alignment VM.10334 (1) onto studs.

    6.  
  6. Install the exhaust manifold (2) and tighten nuts finger tight.

    7.  
  7. Remove the Tool, Exhaust Manifold Alignment VM.10334 (1). Install and tighten nuts finger tight.

    8.  
  8. Using the tightening sequence shown, tighten the exhaust manifold nuts to 36 N·m (27 ft. lbs.).

    9.  
  9. Repeat the same tightening procedure again.

    10.  
  10. Connect the turbocharger module harness connector (1).

    11.  
  11. Install the turbocharger oil return line (2) and bolt (1). Tighten to 15 N·m (133 in. lbs.).

    12.  
  12. Install the turbocharger oil feed line. Tighten to 24 N·m (18 ft. lbs).

    13.  
  13. Install the exhaust manifold heat shield (2) and the heat shield bolts (1).

    14.  
  14. Position the turbocharger to engine support brace and install the bolts. Tighten to 32 N·m (23 ft. lbs).

    15.  
  15. Install the catalytic converter (Refer to 11 - Exhaust System/CONVERTER, Catalytic - Installation) .

    16.  
  16. If equipped, install the transmission fill tube (2) and the bolt (1). Tighten to 11 N·m 97 in. lbs.).

    17.  
  17. If equipped, install the lower transmission fill tube bolt (1). Tighten to 11 N·m 97 in. lbs.).

    18.  
  18. Install the turbo charger outlet hose to CAC inlet.

    19.  
  19. Install the air cleaner outlet tube to turbocharger inlet elbow (1).

    20.  
  20. Install the air cleaner outlet tube.

    21.  
  21. Connect the crankcase vent hose (1) to the oil separator (2).

    22.  
  22. Install the air cleaner body (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner - Installation) .

    23.  
  23. Connect the negative battery cable.

    24.