Exhaust Manifold: Service and Repair

REMOVAL PROCEDURE





1. Open the hood.
2. Disconnect the battery negative cable from the battery.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

3. Remove the oil level indicator and tube from the engine block.
4. Remove the EGR valve pipe from the left exhaust manifold.
5. Remove the spark plugs cylinder head.
6. Raise the vehicle and support the vehicle with safety stands.
7. Remove the exhaust pipe from the exhaust manifold.
- Lower the vehicle.





8. Remove the exhaust manifold retaining nuts.
9. Remove the exhaust manifolds from the cylinder head.
10. Remove the exhaust manifold gasket from the cylinder head.
11. Clean and check the gasket mating surface and the cylinder head. Refer to Cylinder Head Clean and Inspect under Engine Unit Repair.

INSTALLATION PROCEDURE

IMPORTANT: Install the exhaust manifold gasket with the stamped 7.4 facing away from the cylinder head.





1. Install the exhaust manifold gasket to the cylinder head.





2. Install the exhaust manifold to the cylinder head.
3. Install the exhaust manifold retaining bolts
- Tighten the bolts to 30 Nm (22 ft. lbs.).
- Tighten the center bolt to 54 Nm (40 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





4. Install the spark plug heat shields.
Tighten the bolts to 20 Nm (15 ft. lbs.).

5. Install the oil level indicator tube to the exhaust manifold.
6. Install the spark plugs to the cylinder head.
7. Raise the vehicle and support with safety stands.
8. Install the exhaust pipes to the exhaust manifolds.
- Lower the vehicle.





9. Install the EGR pipe to the intake manifold and the exhaust manifold.
10. Tighten the bolts to 60 Nm 46 ft. lbs.
11. Connect the battery negative cable to the battery.
12. Close the hood.