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Exhaust Manifold

REMOVAL & INSTALLATION

1.5L and 1.8L Engine

Fig. 1: Exploded view of the exhaust manifold — 1.5L engine

Fig. 2: Exhaust manifold exploded view — 1.8L engine

  1. Disconnect battery negative cable.
  2. Raise the vehicle and support safely.
  3. Remove the exhaust pipe to exhaust manifold nuts and separate exhaust pipe. Discard gasket.
  4. Lower vehicle.
  5. Remove electric cooling fan assembly, if necessary.
  6. If the oxygen sensor is located in the manifold, remove the sensor.
  7. Disconnect necessary EGR components.
  8. Remove outer exhaust manifold heat shield and engine hanger. Detach the electrical connector and remove the oxygen sensor.
  9. Remove the exhaust manifold mounting bolts, the inner heat shield and the exhaust manifold.

    To install:

  10. Clean all gasket material from the mating surfaces and check the manifold for damage.
  11. Using a new gasket, install the manifold. For 1.5L engines, tighten the nuts in a crisscross pattern to 13 ft. lbs. (18 Nm). For 1.8L engines, tighten the inner nuts in a crisscross pattern to 13 ft. lbs. (18 Nm) and tighten the two outer (larger) nuts to 22 ft. lbs. (30 Nm).
  12. Install the heat shields.
  13. Connect EGR components.
  14. If removed, install the oxygen sensor.
  15. Install the electric cooling fan assembly as required.
  16. Install a new flange gasket and connect the exhaust pipe.
  17. Connect the negative battery cable and check for exhaust leaks.
1.6L and 2.0L Engines

Fig. 3: Exhaust manifold exploded view — 2.0L SOHC engine

Fig. 4: Exhaust manifold exploded view — 1.6L and 2.0L (non-turbo) DOHC engine

Fig. 5: Exhaust manifold exploded view — 2.0L (turbo) DOHC engine

  1. Disconnect the negative battery cable.
  2. Raise the vehicle and support safely.
  3. Remove the front exhaust pipe to exhaust manifold nuts and separate exhaust pipe. Discard the gasket.
  4. Lower the vehicle.
  5. If equipped with air conditioning, remove condenser cooling fan assembly.
  6. Using special tool MD998703 or equivalent, disconnect and remove the oxygen sensor.
  7. Remove outer exhaust manifold heat shield and the engine hanger.
  8. Remove the exhaust manifold mounting nuts, the inner heat shield and the exhaust manifold from the engine.

    To install:

  9. Clean all gasket material from the mating surfaces and check the manifold for damage or cracking.
  10. Using a new gasket, install the exhaust manifold, to the engine. Tighten the nuts to in a crisscross pattern to 11–14 ft. lbs. (15–20 Nm) for 2.0L SOHC engine or to 18–22 ft. lbs. (25–30 Nm) for 1.6L and 2.0L DOHC engine.
  11. Install the outer heat shield and tighten the mounting bolts to 10 ft. lbs. (14 Nm).
  12. Install the electric cooling fan assembly, if removed.
  13. Using a new flange gasket, connect the exhaust pipe and tighten the mounting nuts to 29–36 ft. lbs. (40–50 Nm).
  14. Connect the negative battery cable and check for exhaust leaks.
2.4L Engine

Fig. 6: Remove the exhaust pipe-to-exhaust manifold nuts

Fig. 7: Remove the hanger retaining bolt . . .

Fig. 8: . . . then separate the pipe from the manifold

Fig. 9: Remove the heat shield retaining bolts . . .

Fig. 10: . . . then remove the heat shield from the exhaust manifold

Fig. 11: Remove the exhaust manifold retaining nuts

Fig. 12: Remove the engine lifting eye from the manifold . . .

Fig. 13: . . . then remove the manifold from the cylinder head

Fig. 14: Remove the exhaust manifold gasket, thoroughly clean the mounting surfaces, and replace the gasket

  1. Disconnect battery negative cable.
  2. Raise the vehicle and support safely.
  3. Remove the exhaust pipe-to-exhaust manifold nuts, the hanger retaining bolt, then separate the exhaust pipe. Discard the gasket.
  4. Remove the outer exhaust manifold heat shield and engine hanger.
  5. Remove the exhaust manifold mounting nuts and the exhaust manifold from the engine.

    To install:

  6. Clean all gasket material from the mating surfaces and check the manifold for damage or cracking.
  7. Install a new gasket and install the manifold. Tighten the nuts to in a crisscross pattern to 18–21 ft. lbs. (25–29 Nm).
  8. Install the heat shields and tighten the mounting bolts 10 ft. lbs. (14 Nm).
  9. Install a new flange gasket and connect the exhaust pipe. Tighten the mounting nuts to 32 ft. lbs. (44 Nm).
  10. Connect the negative battery cable and check for exhaust leaks.
3.0L Engines

Fig. 15: Exploded view of the exhaust manifold and related components — 3.0L SOHC engine

Fig. 16: Exploded view of the exhaust manifold — 3.0L DOHC engine

CAUTION
Do not attempt the work on the exhaust system until it has completely cooled.

  1. Disconnect battery negative cable.
  2. Raise the vehicle and support safely.
  3. Remove the exhaust pipe to exhaust manifold nuts and remove the front exhaust pipe.
  4. Lower the vehicle.
  5. If removing the front manifold, remove condenser electric cooling fan assembly.
  6. For the DOHC engine, if removing the front manifold, remove the alternator and mounting bracket from the vehicle.
  7. For the DOHC engine, separate the A/C compressor from the mounting bracket. Leaving the hoses connected, position the compressor aside.
  8. If removing the front manifold, remove the oil dipstick and tube from the engine.
  9. For the DOHC engine, if removing the front manifold, remove the heat protector.
  10. If removing the rear manifold, disconnect the EGR tube.
  11. For the SOHC engine, if removing the rear manifold, remove the intake plenum stay and the roll stopper bracket.
  12. Unplug the electrical connector and remove the oxygen sensor.
  13. Remove the exhaust manifold mounting bolts the manifold.

    To install:

  14. Clean all gasket material from the mating surfaces and check the manifold for damage.
  15. Install a new gasket and install the manifold. Tighten the nuts in a crisscross pattern to 21 ft. lbs. (30 Nm) for the SOHC engine or to 14 ft. lbs. (19 Nm) for the DOHC engine.
  16. Install the heat shields.
  17. Connect the EGR tube and intake plenum stay and roll stopper bracket, if removed.
  18. Install the oxygen sensor.
  19. Install the electric cooling fan assembly, A/C compressor, dipstick tube and alternator, as required.
  20. Install a new flange gasket and connect the exhaust pipe or converter assembly.
  21. Install the drive belt(s) and adjust for proper tension.
  22. Connect the negative battery cable and check for exhaust leaks.
3.5L Engine

Fig. 17: Exhaust manifold exploded view — 3.5L engine

CAUTION
Do not attempt the work on the exhaust system until it has completely cooled.

  1. Disconnect battery negative cable.
  2. Raise the vehicle and support safely.
  3. Remove the exhaust pipe to exhaust manifold nuts and remove the front exhaust pipe.
  4. Lower the vehicle.
  5. If removing the front manifold, remove the radiator and cooling fan assembly.
  6. If removing the front manifold, remove the alternator.
  7. Remove the heat protector(s).
  8. If removing the rear manifold, disconnect the EGR tube.
  9. Remove the exhaust manifold mounting bolts the manifold.

    To install:

  10. Clean all gasket material from the mating surfaces and check the manifold for damage.
  11. Install a new gasket and install the manifold. Tighten the nuts in a crisscross pattern to 21 ft. lbs. (30 Nm).
  12. Install the heat protector(s).
  13. If installing the rear manifold, replace the gasket and connect the EGR tube.
  14. If installing the front manifold, install the radiator and cooling fan assembly.
  15. If installing the front manifold, install the alternator.
  16. Install the drive belt(s) and adjust for proper tension.
  17. Raise and safely support the vehicle securely on jackstands.
  18. Install a new flange gasket and connect the exhaust pipe or converter assembly.
  19. Lower the vehicle.
  20. Connect the negative battery cable and check for exhaust leaks.

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