Cherokee, Grand Cherokee, 1999-2005

Exhaust Manifold

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Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accessory drive belt
     
    Power steering pump and brackets, if equipped
     
    Fuel line
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Fuel injector connectors
     
    Closed Crankcase Ventilation (CCV) system
     
    Manifold Absolute Pressure (MAP) sensor vacuum line
     
    Brake booster vacuum line
     
    Exhaust front pipe
     
    Intake manifold and discard the gaskets
     
    Exhaust manifold and discard the gaskets
     

  8.  

To install:

Click image to see an enlarged view

Fig. Manifold head torque sequence-2.5L engine

  1. Install or connect the following:

    New gasket over the locating dowels
     
    Exhaust manifold to the studs and tighten the nuts finger-tight
     

  2.  
  3. Install the intake manifold. Torque the fasteners in sequence as follows:
    1. Step 1: Bolt 1 to 30 ft. lbs. (41 Nm).
    2.  
    3. Step 2: Fasteners 2-7 to 23 ft. lbs. (31 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Exhaust front pipe
     
    Brake booster vacuum line
     
    MAP sensor vacuum line
     
    CCV system
     
    Fuel injector connectors
     
    HO 2 S sensor connector
     
    IAT sensor connector
     
    ECT sensor connector
     
    IAC valve connector
     
    TP sensor connector
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Fuel line
     
    Power steering pump and brackets, if equipped
     
    Accessory drive belt
     
    Air intake hose
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

3.7L Engines
Left Side
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative cable from the battery.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the exhaust heat shields.
  12.  
  13. Remove bolts, nuts and washers attaching manifold to cylinder head.
  14.  
  15. Remove manifold and gasket from the cylinder head.
  16.  

To install:


WARNING
If the studs came out with the nuts when removing the engine exhaust manifold, install new studs. Apply sealer on the coarse thread ends. Water leaks may develop at the studs if this precaution is not taken.

  1. Position the engine exhaust manifold and gasket on the two studs located on the cylinder head. Install conical washers and nuts on these studs.
  2.  
  3. Install remaining conical washers. Starting at the center arm and working outward, tighten the bolts and nuts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the exhaust heat shields.
  6.  
  7. Raise and support the vehicle.
    WARNING
    Over tightening heat shield fasteners, may cause shield to distort and/or crack.

  8.  
  9. Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 25 ft. lbs. (34 Nm).
  10.  

Right Side
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative cable from the battery.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the bolts and nuts attaching the exhaust pipe to the engine exhaust manifold.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the exhaust heat shield.
  12.  
  13. Remove bolts, nuts and washers attaching manifold to cylinder head.
  14.  
  15. Remove manifold and gasket from the cylinder head.
  16.  

To install:


WARNING
If the studs came out with the nuts when removing the engine exhaust manifold, install new studs. Apply sealer on the coarse thread ends. Water leaks may develop at the studs if this precaution is not taken.

  1. Position the engine exhaust manifold and gasket on the two studs located on the cylinder head. Install conical washers and nuts on these studs.
  2.  
  3. Install remaining conical washers. Starting at the center arm and working outward, tighten the bolts and nuts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the exhaust heat shields.
  6.  
  7. Raise and support the vehicle.
    WARNING
    Over tightening heat shield fasteners, may cause shield to distort and/or crack.

  8.  
  9. Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 25 ft. lbs. (34 Nm).
  10.  

4.0L Engine

For exhaust manifold Removal & Installation, refer to the procedure under Intake Manifold.

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Power distribution center
     
    Battery tray
     
    Windshield washer fluid bottle
     
    Air cleaner assembly
     
    Accessory drive belt
     
    A/C compressor
     
    A/C accumulator bracket
     
    Heater hoses
     
    Exhaust manifold heat shields
     
    Exhaust Y-pipe
     
    Starter motor
     
    Exhaust manifolds
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifolds, using new gaskets. Torque the bolts to 18 ft. lbs. (25 Nm), starting with the inner bolts and work out to the ends.
     
    Starter motor
     
    Exhaust Y-pipe
     
    Exhaust manifold heat shields
     
    Heater hoses
     
    A/C accumulator bracket
     
    A/C compressor
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Windshield washer fluid bottle
     
    Battery tray
     
    Power distribution center
     
    Battery
     

  2.  
  3. Fill and bleed the cooling system.
  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

5.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove exhaust pipe to manifold bolts.
  8.  
  9. Remove engine mount to frame fasteners.
  10.  
  11. Using suitable jack, raise engine enough to remove manifolds.
    NOTE
    Do not damage engine harness while raising the engine.

  12.  
  13. Remove the engine mount.
  14.  
  15. Remove heat shield.
  16.  
  17. Remove manifold bolts using sequence provided.
  18.  
  19. Remove manifold and gasket.
  20.  

To install:

Click image to see an enlarged view

Fig. Left side exhaust manifold-5.7L engine



Click image to see an enlarged view

Fig. Right side exhaust manifold-5.7L engine

  1. Inspect manifold for cracks.
  2.  
  3. Inspect mating surfaces of manifold for flatness with a straightedge. Gasket surfaces must be flat within 0.2mm per 300mm (0.008 inch per foot).
  4.  
  5. Install manifold gasket and manifold.
  6.  
  7. Install manifold bolts and tighten to 25 ft. lbs. (34 Nm).
  8.  
  9. Install heat shield and tighten nuts to 70 inch lbs (8 Nm).
  10.  
  11. Install front engine mount. Torque to 70 ft. lbs. (95 Nm).
  12.  
  13. Lower engine.
    WARNING
    Do not damage engine harness while lowering the engine.

  14.  
  15. Install and tighten right and left side engine mount to frame fasteners. Torque to 70 ft. lbs. (95 Nm).
  16.  
  17. Install exhaust flange to pipe bolts.
  18.  
  19. Lower vehicle.
  20.  
  21. Connect negative battery cable.
  22.  

 
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