Although in most cases the engine does not have an exhaust manifold gasket installed by the factory, aftermarket gaskets are usually available from automotive parts stores. For 6-cylinder models, refer to the combination manifold procedure.
REMOVAL & INSTALLATION4-Cylinder Engines
See Figure 1
- Remove the air cleaner.
- Remove the heat shroud from the exhaust manifold. On turbocharged models, remove the turbocharger.
- Place a block of wood under the exhaust pipe and disconnect the exhaust pipe from the exhaust manifold.
- Remove the exhaust manifold attaching nuts and remove the manifold.
- Install a light coat of graphite grease on the exhaust manifold mating surface and position the manifold on the cylinder head.
- Install the exhaust manifold attaching nuts and tighten them in the sequence shown in the illustration to 1215 ft. lbs. (16-19 Nm).
- Connect the exhaust pipe to the exhaust manifold and remove the wood support from under the pipe.
- Install the air cleaner.
Refer to the combination manifold procedure for details on the removal and installation of the exhaust manifold.V6 and V8 Engines
See Figures 2 through 9
- Disconnect the negative battery cable.
- If removing the right side exhaust manifold, remove the air cleaner and mounting hardware, as well as the heat stove, if equipped.
- On 5.8L and 6.6L engines: if the left exhaust manifold is being removed, first drain the engine oil and remove the oil filter. On 4.2L and 5.0L engines, dipstick and tube moving or removal may be required. Remove any speed control brackets that interfere.
- Disconnect the exhaust pipes from the manifolds.
On certain vehicles with automatic transmission and column shift, it may be necessary to disconnect the selector lever cross-shaft for clearance.
- Disconnect the spark plug wires and remove the spark plugs and heat shields. Disconnect the EGR sensor (models so equipped), and heat control valve vacuum line (models so equipped).
On some engines the spark plug wire heat shields are removed with the manifold. Transmission dipstick tube and Thermactor® air tube removal may be required on certain models. Air tube removal is possible by cutting the tube clamp at the converter.
- Remove the exhaust manifold attaching bolts and washers, and remove the manifold(s).
- Inspect the manifold(s) for damaged gasket surfaces, cracks, or other defects.
- Clean the mating surfaces of the manifold(s), cylinder head and muffler inlet pipe(s).
- Install the manifold(s) in the reverse order of removal. Tighten the mounting bolts evenly (in steps). Refer to the torque specifications chart in this section. Start with the centermost bolt and work outward in both directions.