Jeep Wagoneer/Commando/Cherokee 1984-1998

Exhaust Manifold

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Removal & Installation



2.1L Diesel Engine
  1. Disconnect the negative battery cable. Remove the intake manifold.
  2.  
  3. Disconnect the exhaust pipe from the adapter.
  4.  
  5. Remove the oil supply pipe and the oil return hose from the turbocharger assembly.
  6.  
  7. Disconnect the turbocharger air inlet and outlet hoses.
  8.  
  9. Remove the turbocharger retaining bolts. Remove the turbocharger from the vehicle.
  10.  
  11. Remove the exhaust manifold retaining bolts. Remove the exhaust manifold and gasket. Discard the gasket.
  12.  

To install:
  1. Position the exhaust manifold and gasket on the head.
  2.  
  3. Install the exhaust manifold retaining bolts and tighten them to 31 ft. lbs. (42 Nm).
  4.  
  5. Install the turbocharger.
  6.  
  7. Connect the turbocharger air inlet and outlet hoses.
  8.  
  9. Install the oil supply pipe and the oil return hose at the turbocharger assembly.
  10.  
  11. Connect the exhaust pipe at the adapter.
  12.  
  13. Install the intake manifold.
  14.  
  15. Connect the negative battery cable.
  16.  

2.5L Engine

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Disconnect the exhaust pipe at the manifold.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the fasteners from the exhaust manifold ...



Click image to see an enlarged view

Fig. Fig. 2: ... then remove the manifold from the engine

  1. Remove the fasteners and exhaust manifold.
  2.  

To install:
  1. Clean the intake manifold and cylinder head mating surfaces.
  2.  
  3. Using a new intake manifold gasket, position the intake and exhaust manifolds on the cylinder head and place spacers over the end studs to center the exhaust manifold. Install the end stud nuts and washer clamps but do not tighten.
  4.  
  5. Install washer clamp and bolt at position 1 and tighten to 30 ft. lbs. (41 Nm).
  6.  
  7. Install bolts and washers at positions 2-5 and tighten to 23 ft. lbs. (31 Nm).
  8.  
  9. Tighten end stud nuts (positions 6 and 7) to 23 ft. lbs. (31 Nm).
  10.  
  11. Install all components removed from the intake manifold.
  12.  
  13. Connect the exhaust pipe and tighten the bolts to 23 ft. lbs. (31 Nm).
  14.  
  15. Lower the vehicle.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the engine and inspect it for leaks.
  20.  

2.8L Engine

See Figure 3

LEFT SIDE
  1. Disconnect the negative battery cable. Remove the air cleaner.
  2.  
  3. Remove the air injection hose and manifold (if equipped).
  4.  
  5. Remove the power steering bracket.
  6.  
  7. Raise and support the vehicle safely. Unbolt and remove the exhaust pipe at the manifold.
  8.  
  9. Unbolt and remove the manifold.
  10.  

To install:
  1. Clean the mating surfaces of the cylinder head and manifold. Install the manifold onto the head, and install the retaining bolts finger-tight.
  2.  
  3. Tighten the manifold bolts in a circular pattern, working from the center to the ends, to 25 ft. lbs. (34 Nm) in two stages.
  4.  
  5. Connect the exhaust pipe to the manifold.
  6.  
  7. The remainder of installation is the reverse of removal.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: Exhaust manifolds used on the 2.8L engine

RIGHT SIDE
  1. Disconnect the negative battery cable. Raise and support the vehicle safely.
  2.  
  3. Disconnect the exhaust pipe from the exhaust manifold.
  4.  
  5. Lower the vehicle. Remove the spark plug wires from the plugs. Number them first if they are not already labeled. Remove the cruise control servo from the right inner fender panel, if equipped.
  6.  
  7. Remove the air supply pipes from the manifold. Remove the Pulsair bracket bolt from the rocker cover, on models so equipped, then remove the pipe assembly.
  8.  
  9. Remove the manifold retaining bolts and remove the manifold.
  10.  

To install:
  1. Clean the mating surfaces of the cylinder head and manifold. Position the manifold against the head and install the retaining bolts finger-tight.
  2.  
  3. Tighten the bolts in a circular pattern, working from the center to the ends, to 25 ft. lbs. (34 Nm) in two stages.
  4.  
  5. Install the air supply system. Install the spark plug wires. If equipped install the cruise control servo.
  6.  
  7. Raise and support the vehicle safely. Connect the exhaust pipe to the manifold.
  8.  

4.0L Engine

The intake and exhaust manifolds of the 4.0L must be removed together. Please refer to the combination manifold procedure in this section.

5.2L and 5.9L Engines

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the exhaust manifold heat shields.
  4.  
  5. Remove the spark plug wire loom and cables from the mounting stud at the rear of the valve cover and position the cables at the top of the valve cover.
  6.  
  7. Label and disconnect the 2 hoses from the EGR valve.
  8.  
  9. Disconnect the electrical connector and hoses from the EGR transducer.
  10.  
  11. Remove the EGR valve and discard the gasket.
  12.  
  13. Disconnect the oil pressure sending unit electrical connector.
  14.  
  15. Using oil pressure sending unit remover C-4597 or equivalent, remove the sending unit.
  16.  
  17. Loosen the EGR mounting nut from the intake manifold.
  18.  
  19. Remove the mounting bolts and EGR tube. Discard the gasket.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Disconnect the exhaust pipes from the manifolds.
  24.  
  25. Lower the vehicle.
  26.  
  27. Remove the fasteners and exhaust manifold.
  28.  

To install:


Click image to see an enlarged view

Fig. Fig. 4: Exhaust manifolds used on the 5.2L and 5.9L engines

If the manifold mounting studs came out with the fasteners, replace the studs.

  1. Position the manifold and install the conical washers on the studs.
  2.  
  3. Install new bolt and washer assemblies into the remaining holes. Working from the center outward, tighten the fasteners to 20 ft. lbs. (27 Nm).
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Connect the exhaust pipes to the manifolds and tighten the fasteners to 23 ft. lbs. (31 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Clean the EGR and tube gasket mating surfaces.
  12.  
  13. Install a new gasket onto the exhaust manifold ends of the EGR tube and install the tube. Tighten the tube nut to the intake manifold and tighten the tube-to-exhaust manifold bolts to 204 inch lbs. (14 Nm).
  14.  
  15. Coat the threads of the oil pressure sending unit with sealer taking care not to apply sealant to the opening.Install the sending unit and tighten it to 130 inch lbs. (14 Nm) and connect the electrical connector.
  16.  
  17. Install the EGR valve and new gasket to the intake manifold and tighten the bolts to 200 inch lbs. (23 Nm).
  18.  
  19. Position the EGR transducer and connect the vacuum lines and electrical connector.
  20.  
  21. Position the spark plug cables and loom into place and connect the cables.
  22.  
  23. Install the exhaust heat shields and tighten the bolts to 20 ft. lbs. (27 Nm).
  24.  
  25. Connect the negative battery cable.
  26.  

 
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