Exhaust Manifold

REMOVAL & INSTALLATION

2.3L and 2.5L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Intake Air Temperature (IAT) sensor
   • Air cleaner outlet tube
   • Differential Pressure Feedback (DPFE) sensor and move it aside
   • Exhaust Gas Recirculation (EGR) transducer lines at the tube
   • Loosen and remove the EGR valve-to-exhaust manifold tube
   • Catalytic converter from the exhaust manifold
   • Rear engine lifting eye nuts
   • Exhaust manifold and discard the gasket

   To install:

   Fig. 1: Tighten the exhaust manifold bolts in 2 stages

3. Clean the mating surfaces on the exhaust manifold and the cylinder head.
4. Install a new gasket and the exhaust manifold. Torque the bolts in sequence as follows:
   1. 16 ft. lbs. (23 Nm).
   2. 59 ft. lbs. (80 Nm).
5. Install or connect the following:
   • Rear engine lifting eye. Torque the bolts to 15 ft. lbs. (20 Nm).
   • Catalytic converter to the exhaust manifold
   • EGR valve to the exhaust manifold tube
   • EGR transducer lines
   • DPFE sensor
   • Air cleaner outlet tube
   • IAT sensor
   • Negative battery cable
6. Start the vehicle and check for leaks, repair if necessary.

3.0L Engine

LEFT SIDE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Install or connect the following:
   • Negative battery cable
   • Exhaust flange nuts
   • Exhaust Gas Recirculation (EGR) valve from the exhaust manifold tube
   • Oil lever indicator and bracket
   • Exhaust manifold and discard the gasket

   To install:

   Fig. 2: Tighten the exhaust manifold bolts in sequence–3.0L left side

3. Clean the mating surfaces for the exhaust manifold and cylinder head.
4. Install a new gasket and the exhaust manifold. Torque the bolts in sequence to:
   1. 89 inch lbs. (10 Nm).
   2. 15 ft. lbs. (20 Nm).
5. Install or connect the following:
   • Oil lever indicator tube and bracket. Torque the bolt to 12 ft. lbs. (16 Nm).
   • EGR valve to the exhaust manifold tube. Torque the fastener to 26 ft. lbs. (35 Nm).
   • Exhaust flange. Torque the nuts to 25 ft. lbs. (34 Nm).
   • Negative battery cable
6. Start the vehicle and check for leaks, repair if necessary.

RIGHT SIDE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Exhaust manifold flange
   • Ignition coil support bracket
   • Exhaust manifold and discard the gasket

   To install:

   Fig. 3: Tighten the right side exhaust manifold bolts in the proper sequence–3.0L

3. Clean the mating surfaces for the exhaust manifold and cylinder head
4. Install a new gasket and the exhaust manifold. Torque the bolts is sequence to:
   1. 89 inch lbs. (10 Nm).
   2. 18 ft. lbs. (25 Nm).
5. Install or connect the following:
   • Ignition coil support bracket. Torque the bolts to 15 ft. lbs. (20 Nm).
   • Exhaut flange nuts. Torque the nuts to 33 ft. lbs. (46 Nm).
   • Negative battery cable
6. Start the vehicle and check for leaks, repair if necessary.

4.0L OHV Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Oil level indicator tube and bracket
   • Exhaust pipe-to-manifold bolts
   • Power steering pump hoses, if removing the left-hand manifold
   • Hot air intake shroud that is bolted around the manifold, if removing the right-hand manifold
   • Exhaust manifold and gasket

   To install:

3. Clean all mating surfaces for the exhaust manifold and cylinder head.
4. Install or connect the following:
   • New gasket and the exhaust manifold. Torque the right side bolts to 18 ft. lbs. (25 Nm) and the left side bolts to 16 ft. lbs. (22 Nm).
   • Exhaust pipe to the manifold
   • Oil level bracket. Torque the bolt to 17 ft. lbs. (23 Nm).
   • Negative battery cable
5. Start the vehicle and check for leaks, repair if necessary.

   Fig. 4: Tighten the right side exhaust manifold in sequence

   Fig. 5: Tighten the left side exhaust manifold in sequence