Exhaust Manifold Replacement 2.4L

1. Disconnect the Oxygen sensor (O2S) connector.



2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Notice: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.




3. Remove the flex decoupler to exhaust manifold bolts.



4. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold.
5. Lower the vehicle.
6. Remove cruise control module and position aside. Refer to Cruise Control Module Replacement in Cruise Control.
7. Remove the exhaust manifold heat shield bolts and shield.
8. Remove oil level indicator. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical.
9. Remove the exhaust manifold nuts.
10. Remove the exhaust manifold and gasket.
11. Clean all sealing surfaces.

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




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 exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 13 N·m (115 lb in).

4. Install oil level indicator tube and indicator. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical.



5. Install the exhaust manifold heat shield and bolts.

Tighten
Tighten the exhaust manifold heat shield bolts to 14 N·m (124 lb in).

6. Install cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



8. Install the flex decoupler to exhaust manifold bolts.

Tighten
Tighten the flex decoupler to exhaust manifold bolts to 35 N·m (26 lb ft).

9. Lower the vehicle.
10. Connect the Oxygen sensor (O2S) connector.