Exhaust Manifold

REMOVAL & INSTALLATION

2.2L Engine

1. Raise and support the truck.
2. Remove the two attaching nuts from the exhaust pipe at the manifold.
3. Remove the manifold attaching nuts.
4. Remove the manifold.
5. Apply a light film of graphite grease to the exhaust manifold mating surfaces before installation.
6. Install the manifold on the studs and install the attaching nuts. Torque the attaching nuts to specifications.
7. Install a new exhaust pipe gasket. Connect the exhaust pipe gasket. Connect the exhaust pipe and tighten the nuts to 16–21 ft. lbs. (22–28 Nm).

2.6L Engine

1987-88

1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly.
3. Remove the belt from the power steering pump.
4. Raise the vehicle and make sure it is supported safely.
5. Remove the exhaust pipe from the manifold.
6. Disconnect the air injection tube assembly from the exhaust manifold and lower the vehicle.
7. Remove the power steering pump assembly and move to one side.
8. Remove the heat cowl from the exhaust manifold.
9. Remove the exhaust manifold retaining nuts and remove the assembly from the vehicle.
10. Remove the carburetor air heater from the manifold.
11. Separate the exhaust manifold from the catalytic converter by removing the retaining screws.
12. Clean gasket material from cylinder head and exhaust manifold gasket surfaces. Check mating surfaces for cracks or distortion.

    To install:

13. Install a new gasket between the exhaust manifold and catalytic converter. Install mounting screws and tighten to 24 ft. lbs. (32 Nm).
14. Install the carburetor air heater on manifold and tighten to 80 inch lbs. (9 Nm).
15. Lightly coat the new exhaust manifold gasket with sealant (P/N 3419115) or equivalent on cylinder head side.
16. Install the exhaust manifold and mounting nuts. Tighten to 16–21 ft. lbs. (22–28 Nm).
17. Install the heat cowl to manifold and tighten screws to 80 inch lbs. (9 Nm).
18. Install the air cleaner support bracket.
19. Install the power steering pump assembly.
20. Install the air injection tube assembly to air pump.
21. Raise the vehicle and install air injection tube assembly to exhaust manifold.
22. Install the exhaust pipe to manifold.
23. Lower the vehicle and install power steering belt.
24. Fill the cooling system.
25. Install the air cleaner assembly.
26. Connect the negative battery cable.

1989–93

1. Disconnect the battery ground.
2. Drain the cooling system.

   CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

3. Remove the oil dipstick tube.
4. It may make the job easier to remove the coolant bypass pipe.
5. Disconnect the exhaust pipe from the manifold.
6. Remove the heat shield.
7. Unbolt and remove the manifold. Discard the gasket.
8. Clean all mating surfaces. Place a new gasket and exhaust manifold in position and loosely install the mounting bolts. After all of the manifold bolts and attached components are loosely installed, secure all mounting bolts. Tighten the bolts to 18 ft. lbs. (24 Nm).

MPV

1. Disconnect the negative battery cable. Raise and safely support the vehicle.
2. Disconnect the exhaust pipe from the exhaust manifold. If necessary, disconnect the electrical connector from the oxygen sensor.
3. Lower the vehicle.
4. Remove the exhaust manifold insulator, if equipped.
5. If necessary, remove the engine oil dipstick and the dipstick tube.
6. On models with the 3.0L engine, disconnect or remove the exhaust manifold crossover pipe.
7. Remove the exhaust manifold attaching bolts/nuts and remove the exhaust manifold.
8. Clean all mating surfaces. Place a new gasket and exhaust manifold in position and loosely install the mounting bolts. After all of the manifold bolts and attached components are loosely installed, secure all mounting bolts. Tighten the exhaust manifold attaching bolts/nuts to 19 ft. lbs. (25 Nm).

4.0L Engine

LEFT SIDE

1. Disconnect the negative battery cable. Remove the oil level indicator tube bracket.
2. Remove the power steering pump hoses, if necessary for working clearance.
3. Remove the exhaust pipe-to-manifold bolts.
4. Unbolt and remove the manifold.
5. Clean and lightly oil all fastener threads.
6. Clean the mating surfaces of the manifold and cylinder head. Position the manifold on the cylinder head and install the fasteners, replace all gaskets, if equipped. Install the remaining removed components. Tighten the manifold bolts to 19 ft. lbs (26 Nm).; the exhaust pipe nuts to 20 ft. lbs. (27 Nm). Tighten both exhaust pipe retaining nuts in equal amounts to correctly seat the inlet pipe flange.

RIGHT SIDE

1. Drain the cooling system.

   CAUTION
   When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2. Remove the heater hose support bracket.
3. Disconnect the heater hoses.
4. Remove the exhaust pipe-to-manifold nuts.
5. Unbolt and remove the manifold.
6. Clean the mating surfaces of the manifold and cylinder head. Position the manifold on the cylinder head and install the fasteners, replace all gaskets, if equipped. Install the remaining removed components. Tighten the manifold bolts to 19 ft. lbs. (26 Nm).; the exhaust pipe nuts to 20 ft. lbs. (27 Nm). Tighten both exhaust pipe retaining nuts in equal amounts to correctly seat the inlet pipe flange.