Exhaust Manifold: Service and Repair

EXHAUST MANIFOLD
REMOVAL
1. Disconnect negative battery cable.
2. Raise vehicle on hoist.
3. Remove complete exhaust system.
4. Remove rear engine mount and transaxle bracket.








5. Disconnect connector tube from check valve (if equipped). Squeeze connector as shown and pull (Fig. 105) (Fig. 106).





6. Remove exhaust manifold heat shield (Fig. 107).
7. Disconnect oxygen sensor electrical connector.
8. Remove exhaust manifold retaining fasteners and remove exhaust manifold.
9. Remove and discard manifold gasket.

CLEANING
1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.

INSPECTION
1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length.
2. Inspect manifolds for cracks or distortion. Replace manifold as necessary.

INSTALLATION
There are two different exhaust manifolds that are used on the 2.41, engine. The PZEV manifold has a check valve attached to it. Each manifold has a different torque sequence that must be followed.
1. Install new exhaust manifold gasket. DO NOT APPLY SEALER.








2. Position exhaust manifold in place. Tighten fasteners in sequence shown in (Fig. 108) for non-PZEV engines to 23 Nm (200 inch lbs.). For PZEV engines tighten bolts (Fig. 109) to 23 Nm (200 inch lbs.). Repeat this procedure until all fasteners are at specified torque.
3. Install exhaust manifold heat shield.
4. Install check valve tighten bolts to 12 Nm (105 inch lbs.) (if equipped).
5. Connect connector tube to check valve by pushing fitting over check valve.
6. Connect oxygen sensor electrical connector.
7. Install rear engine mount and transaxle bracket.
8. Install exhaust system. Tighten fasteners to 28 Nm (250 inch lbs.).
9. Lower vehicle.
10. Connect negative battery cable.