Exhaust Manifold Replacement 2.4L

Caution: Refer to Battery Disconnect Caution in the Preface section.




1. Disconnect the negative battery cable.
2. Disconnect the front heated oxygen sensor connector.



3. Remove the exhaust manifold heat shield retaining bolts.
4. Remove the exhaust manifold heat shield retaining bolts.



5. Remove the pup converter-to-exhaust front pipe retaining nuts.
6. Remove the exhaust front pipe mounting bracket bolt and nut.



7. Remove the exhaust manifold retaining nuts in the sequence shown.
8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket.
10. Clean the sealing surfaces of the exhaust manifold and the cylinder head.

1. Install a new exhaust manifold gasket.
2. Install the exhaust manifold.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the exhaust manifold retaining nuts and tighten in the sequence shown.

Tighten
Tighten the exhaust manifold retaining nuts to 22 N·m (16 lb ft).




4. Install the exhaust front pipe-to-pup converter. Refer to Front Pipe Replacement .

Tighten

•	Tighten the pup converter-to-exhaust front pipe retaining nuts to 40 N·m (30 lb ft).

•	Tighten the exhaust front pipe mounting bracket bolt and nut to 40 N·m (30 lb ft).




5. Install the exhaust manifold heat shield.

Tighten
Tighten the exhaust manifold heat shield bolts to 15 N·m (11 lb ft).




6. Connect the front heated oxygen sensor connector.
7. Connect the negative battery cable.

Exhaust Manifold Replacement 2.0L Diesel

Caution: Refer to Battery Disconnect Caution in the Preface section.




1. Disconnect the negative battery cable
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement .



4. Remove the PCV valve and adapter. Refer to Positive Crankcase Ventilation Valve Replacement and Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .



5. Remove the exhaust heat shield.



6. Remove the pre-catalyst. Refer to Catalytic Converter Replacement .
7. Remove the turbocharger from the exhaust manifold. Refer to Turbocharger Replacement .



8. Remove the EGR cooler inlet pipe from the EGR valve with the gasket.
9. Remove the exhaust manifold with the EGR cooler inlet pipe.
10. Remove the EGR cooler inlet pipe from the exhaust manifold.

1. Install the EGR cooler inlet pipe to the exhaust manifold.
2. Install the exhaust manifold to the cylinder head with a new gasket.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the EGR cooler inlet pipe to the EGR valve with a new gasket.

Tighten

•	Tighten the EGR cooler inlet pipe nuts (to exhaust manifold) to 33 N·m (24.3 lb ft).

•	Tighten the exhaust manifold nuts to 33 N·m (24.3 lb ft).

•	Tighten the EGR cooler inlet pipe bolts (to EGR valve) to 20 N·m (14.8 lb ft).




4. Install the exhaust manifold heat shield.

Tighten
Tighten the exhaust manifold heat shield nuts and bolt to 20 N·m (14.8 lb ft).