Exhaust Manifold

REMOVAL & INSTALLATION

2.4L Engine

1. Remove or disconnect the following:
   • Negative battery cable

   CAUTION
   Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

2. Heat cowl from the exhaust manifold
3. Aspirator valve assembly, if equipped
4. Oil dipstick and guide
5. Oxygen (O2S) sensor connector and ground cable, if equipped
6. Exhaust pipe from the manifold
7. Exhaust manifold and gasket from the engine

   To install:

8. Install or connect the following:
   • Exhaust manifold. Torque the M8 mounting nuts to 22 ft. lbs. (29 Nm) and the M10 mounting bolts 36 ft. lbs. (49 Nm). starting from the middle and working outward.
   • O2S sensor connector and ground cable, if equipped
   • Exhaust pipe to the manifold. Torque the nuts to 35ft. (49 Nm).
   • Aspirator valve assembly, if removed
   • Heat cowl to the exhaust manifold. Torque the bolts to 117 inch lbs. (13 Nm).
   • Negative battery cable
9. Start the engine and check for exhaust leaks.

3.0L and 3.5L Engines

1. Remove or disconnect the following:
   • Negative battery cable
   • Exhaust pipe from the exhaust manifolds
   • Oil dipstick, guide and O-ring
   • Heat shields
   • Exhaust manifolds
2. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.

   To install:

3. Install or connect the following:
   • New gasket and exhaust manifold. Torque the nuts to 33 ft. lbs. (44 Nm) on 3.0L engines and 22 ft. lbs. (29 Nm) on 3.5L engines.
   • Heat shield, Torque the bolts to 10 ft. lbs. (14 Nm).
   • Exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).
   • Oil dipstick, guide and new O-ring
   • Negative battery cable
4. Start the engine and check for exhaust leaks.