Jeep Wrangler/YJ 1987-1995 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



2.5L Engine

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Intake/exhaust manifold installation and torque sequence-1989-91 2.5L engine



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Fig. Fig. 2: Intake/exhaust manifold installation and torque sequence-1992-95 2.5L engine



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Fig. Fig. 3: Removing the exhaust manifold retaining bolts



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Fig. Fig. 4: Removing the exhaust manifold from the vehicle

  1. Remove the intake manifold.
  2.  
  3. Disconnect the EGR tube.
  4.  
  5. Disconnect the exhaust pipe at the manifold.
  6.  
  7. Disconnect the oxygen sensor wire.
  8.  
  9. Support the manifold and remove the nuts from the studs.
  10.  
  11. If a new manifold is being installed, transfer the oxygen sensor. Torque the sensor to 35 ft. lbs. (47 Nm).
  12.  
  13. Thoroughly clean the gasket mating surfaces of the manifold and head.
  14.  
  15. Install the manifold, using a new gasket. Torque the nuts to 23 ft. lbs. (31 Nm).
  16.  
  17. Connect the oxygen sensor wire.
  18.  
  19. Connect the exhaust pipe at the manifold.
  20.  
  21. Connect the EGR tube.
  22.  
  23. Install the intake manifold.
  24.  

4.0L and 4.2L Engines

See Figures 5 and 6

The intake and exhaust manifolds on 4.0L and 4.2L engines must be removed together. See the procedure for removing and installing the intake manifold.



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Fig. Fig. 5: Intake/exhaust manifold installation and torque sequence-4.0L engine



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Fig. Fig. 6: Intake/exhaust manifold installation and torque sequence-4.2L engine

 
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