Exhaust Manifold Replacement Right

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable.



2. Remove the oil level indicator and tube from the engine block. Refer to Oil Level Indicator and Tube Replacement .
3. Remove the spark plugs from the cylinder head. Refer to Spark Plug Replacement .
4. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the exhaust pipe from the exhaust manifolds. Refer to Exhaust Pipe Replacement in Engine Exhaust.
6. Lower the vehicle.



7. Remove the nuts and the center bolt that retain the exhaust manifold.
8. Remove the exhaust manifolds from the cylinder head.
9. Remove the exhaust manifold gasket from the cylinder head.
10. Clean and inspect the gasket mating surface and the cylinder head. Refer to Cylinder Head Clean and Inspect .

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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the nuts and the center bolt to the exhaust manifold.

Tighten

1. Tighten the nuts to 30 N·m (22 lb ft).
2. Tighten the center bolt to 54 N·m (40 lb ft).



4. Install the spark plug heat shields.
5. Install the nuts to the spark plug heat shield.

Tighten
Tighten the nuts to 20 N·m (15 lb ft).




6. Install the oil level indicator tube to the exhaust manifold. Refer to Oil Level Indicator and Tube Replacement .
7. Install the spark plugs to the cylinder head. Refer to Spark Plug Replacement .
8. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
9. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Pipe Replacement in Engine Exhaust.
10. Remove the safety stands and lower the vehicle.
11. Connect the battery negative cable.

Exhaust Manifold Replacement Left

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable.



2. Remove the EGR valve inlet pipe from the left exhaust manifold and the intake manifold.
3. Remove the spark plug wires from the spark plugs.



4. Remove the spark plugs from the cylinder head. Refer to Spark Plug Replacement .
5. Remove the spark plug heat shield nuts.
6. Remove the spark plug heat shields.
7. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
8. Remove the exhaust pipe from the exhaust manifolds. Refer to Exhaust Pipe Replacement .
9. Lower the vehicle.



10. Remove the nuts and the center bolt that retain the exhaust manifold.
11. Remove the exhaust manifold from the cylinder head.
12. Remove the exhaust manifold gasket from the cylinder head.
13. Clean and inspect the gasket mating surface and the cylinder head. Refer to Cylinder Head Clean and Inspect .

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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the nuts and the center bolt that retain the exhaust manifold.

Tighten

1. Tighten the exhaust manifold nuts to 30 N·m (22 lb ft).
2. Tighten the exhaust manifold center bolt to 54 N·m (40 lb ft).



4. Install the spark plug heat shields.
5. Install the nuts to the spark plug heat shield.

Tighten
Tighten the nuts to 20 N·m (15 lb ft).

6. Install the spark plugs to the cylinder head. Refer to Spark Plug Replacement .
7. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
8. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Pipe Replacement in Engine Exhaust.
9. Remove the safety stands and lower the vehicle.



10. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.

Tighten
Tighten the EGR valve inlet pipe at the exhaust manifold to 60 N·m (44 lb ft).

11. Install the EGR valve inlet pipe to the intake manifold.

Tighten
Tighten the EGR valve inlet pipe at the intake manifold to 60 N·m (44 lb ft).

12. Install the spark plug wires onto the spark plugs.
13. Connect the battery negative cable to the battery. Refer to Battery Cable Replacement in Engine Electrical.