Exhaust Manifold Replacement - Right Side 2.5L Engine

1. Remove the air cleaner upper case and intake air hose.



2. Detach the oxygen sensor couplers from the mounting bracket (1) and disconnect the oxygen sensor (HO2S1) electrical connectors (2).



3. Disconnect the EGR pipe (1) from the exhaust manifold (2).



4. Remove the exhaust manifold cover bolts (1) and the cover (2).
5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



6. Remove the following from the exhaust manifold and engine block:

•

1 bolt

•

1 nut

•	The exhaust manifold reinforcement bracket (1)

7. Remove the front pipe. Refer to Front Pipe Replacement .
8. Lower the vehicle.
9. Remove the nuts and bolts from the exhaust manifold.
10. Remove the exhaust manifold with the gasket.

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.

Important: When installing a new exhaust system component, always use new gaskets and seals.

1. Install the exhaust manifold with a new gasket.

Tighten
Tighten the manifold bolts and nuts to 30 N·m (21.5 lb ft).

2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Install the front pipe. Refer to Front Pipe Replacement .



4. Install the exhaust manifold reinforcement bracket to the exhaust manifold and engine block.

Tighten

•	Tighten the engine mount-to-exhaust bracket bolt (1) to 54 N·m (40 lb ft).

•	Tighten the exhaust bracket-to-exhaust manifold nut (2) to 50 N·m (37 lb ft).

5. Lower the vehicle.



6. Install the exhaust manifold cover  (2) and the cover bolts (1).

Tighten
Tighten the lower manifold heat shield bolts to 10 N·m (89 lb in).




7. Connect the EGR pipe (1) to the exhaust manifold (2).



8. Attach the oxygen sensor couplers to the mounting bracket (1) and connect the oxygen sensor (HO2S1) electrical connectors (2).
9. Install the air cleaner upper case and intake air hose.