Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement (2.4L)

Removal Procedure

1. Disconnect the cable from the negative battery terminal. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair)
2. Remove the right hand engine under cover.




3. Disconnect the front exhaust pipe assembly.
4. Disconnect the heated oxygen sensor connector.
5. Remove the 2 bolts (1), 2 compression springs and the front exhaust pipe assembly.
6. Remove the gasket from the exhaust manifold.




7. Remove the 4 bolts (1, 2, 3, 4) and the exhaust manifold heat insulator.
8. Remove the air fuel ratio sensor.




9. Remove the bolt (2), nut (1) and manifold support bracket.




10. Remove the bolt (2), nut (1) and the manifold support bracket.




11. Remove the 5 nuts (1, 2, 3, 4, 5) and the exhaust manifold converter sub-assembly.
12. Remove the gasket.




13. Remove the 2 bolts (1, 2) and the exhaust manifold heat insulator.




14. Remove the 4 bolts (1, 2, 3, 4) and the manifold converter heat insulator.

Installation Procedure





Caution: Refer to Fastener Caution (Fastener Caution)

1. Install the manifold converter heat insulator with the 4 bolts (1, 2, 3, 4) and tighten to 12 Nm (9 lb ft).




2. Install the exhaust manifold heat insulator with the 2 bolts (1, 2) and tighten to 12 Nm (9 lb ft).
3. Install a new gasket.




4. Install the exhaust manifold converter sub-assembly with the 5 nuts (1, 2, 3, 4, 5) in the order shown in the illustration and tighten to 37 Nm (27 lb ft).




5. Install the manifold support bracket with the bolt (1) and nut (2) and tighten to 44 Nm (33 lb ft).




6. Install the manifold support bracket with the bolt (2) and nut (1) and tighten to 44 Nm (33 lb ft).
7. Install air fuel ratio sensor.




8. Install the exhaust manifold heat insulator with the 4 bolts (1, 2, 3, 4) and tighten to 12 Nm (9 lb ft).
9. Connect the front exhaust pipe assembly. Refer to Front Pipe Replacement (2.4L AWD) (Service and Repair)Front Pipe Replacement (2.4L FWD) (Service and Repair).
10. Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold.
11. Install right hand engine under cover.
12. Connect cable to negative battery terminal.
13. Inspect for exhaust gas leaks.