Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement (2.4L LE5)

Removal Procedure




1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (Service and Repair).
2. Remove the connector position assurance (CPA) retainer.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector (2).





Note: The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

4. Remove the HO2S (1). Refer to Heated Oxygen Sensor Replacement - Sensor 1 (Service and Repair).




5. Remove the exhaust manifold heat shield bolts.
6. Remove the heat shield.




7. Remove the catalytic converter to exhaust manifold nuts (1).




8. Remove and discard the exhaust manifold nuts.
9. Remove the exhaust manifold.
10. Remove and discard the exhaust manifold gasket.

Installation Procedure




1. Install a NEW exhaust manifold gasket onto the studs.
2. Install the exhaust manifold.
3. Install the NEW exhaust manifold nuts finger tight.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the catalytic converter to exhaust manifold nuts (1).

Tighten the bolts to 50 Nm (37 lb ft).




5. Tighten the exhaust manifold nuts in the sequence shown.

Tighten the nuts to 14 Nm (10 lb ft).




6. Install the heat shield.
7. Install the exhaust manifold heat shield bolts.

Tighten the bolts to 10 Nm (89 lb in).




8. Install the HO2S (1). Refer to Heated Oxygen Sensor Replacement - Sensor 1 (Service and Repair).




9. Connect the HO2S electrical connector (2).
10. Install the CPA retainer.
11. Start the vehicle and inspect for leaks.
12. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (Service and Repair).