Liberty, Wrangler, 1997-2005

Exhaust Manifold

Print

Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  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
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust Y-pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.

  1. Install or connect the following:

    Exhaust manifolds. Torque the fasteners to 20 ft. lbs. (27 Nm), starting with the center nuts and work out to the ends.
     
    Exhaust Y-pipe
     
    EGR tube
     
    Exhaust manifold heat shields
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

 
label.common.footer.alt.autozoneLogo