Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement

Removal Procedure

1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.
Remove the oil level indicator and tube from the engine block. Refer to Oil Level Indicator and Tube Replacement Service and Repair.




2. Remove the EGR valve pipe from the left exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement Service and Repair in Engine Controls-7.4L.
3. Remove the spark plug heat shields.
4. Remove the spark plugs cylinder head. Refer to Spark Plug Replacement Service and Repair in Engine Electrical.
5. Raise the vehicle and support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.

Description:

6. Remove the exhaust pipe from the exhaust manifold.
7. 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 Exhaust Manifold Cleaning and Inspection (without RPO K19) 60. Exhaust Manifold Cleaning and Inspection - without RPO K19).

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.





Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the exhaust manifold retaining bolts

* Tighten the bolts to 30 Nm (22 lb ft).
* Tighten the center bolt to 54 Nm (40 lb ft).




4. Install the spark plug heat shields.

Tighten the bolts to 20 Nm (15 lb ft).

5. Install the oil level indicator tube to the exhaust manifold. Refer to Oil Level Indicator and Tube Replacement Service and Repair.
6. Install the spark plugs to the cylinder head. Refer to Spark Plug Replacement Service and Repair in Engine Electrical.
7. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle Service and Repair in General Information.

Description:

8. Install the exhaust pipes to the exhaust manifolds. Refer to Catalytic Converter Replacement Service and Repair in Engine Exhaust.
9. Install the EGR pipe to the intake manifold and the exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement Service and Repair in Engine Controls.
10. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement (Negative Cable to Engine) Battery Cable Replacement (Negative Cable to Engine)Battery Cable Replacement (Positive Cable) Service and RepairBattery Cable Replacement (Negative Cable to Frame) Battery Cable Replacement (Negative Cable to Frame) in Engine Electrical.
11. Lower the vehicle.