Sebring 2006

Exhaust Manifold

Print

Removal & Installation



2.4L Engines
Non-PZEV Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  4.  
  5. Remove or disconnect the following:

    The exhaust pipe from the exhaust manifold
     
    The exhaust manifold heat shield
     
    The Heated Oxygen Sensor (HO 2 S), if necessary
     
    The exhaust manifold and discard the gasket
     

  6.  

To install:

Click image to see an enlarged view

Fig. Be careful not to damage the oxygen sensor when servicing the exhaust manifold-2.4L engine



Click image to see an enlarged view

Fig. Exhaust manifold torque sequence-2.4L non-PZEV engine

  1. Thoroughly clean all parts. Clean all sealing surfaces of the manifold and cylinder head. Check the manifold gasket surface for flatness with a straightedge and feeler gauge. The surface must be flat within 0.006 inch (0.15mm) per foot (30cm) of manifold length. Inspect the manifold for cracks or distortion. Replace if necessary.
  2.  
  3. Install or connect the following:

    The new exhaust manifold gasket
     
    The exhaust manifold. Torque the bolts, starting at the center and working outward, to 17 ft. lbs. (23 Nm)
     
    The HO 2 S sensor
     
    The heat shield
     
    The exhaust pipe and torque the fasteners to 21 ft. lbs. (28 Nm)
     
    The negative battery cable
     

  4.  
  5. Start the engine and allow it to idle while inspecting the manifold for exhaust leaks.
  6.  

PZEV Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the complete exhaust system.
  8.  
  9. Remove the rear engine mount and transaxle bracket.
  10.  
  11. Disconnect the connector tube from the check valve. (Squeeze connector and pull).
  12.  
  13. Remove the exhaust manifold heat shield.
  14.  
  15. Disconnect the Oxygen Sensor (O 2 S) electrical connector.
  16.  
  17. Remove the exhaust manifold retaining fasteners and remove exhaust manifold.
  18.  
  19. Remove the and discard the exhaust manifold gasket.
  20.  

To install:

  1. Install the new exhaust manifold gasket. DO NOT APPLY SEALER.
  2.  
  3. Position exhaust manifold in place. Tighten fasteners in sequence shown to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-2.4L PZEV engine

  4.  
  5. Install the exhaust manifold heat shield.
  6.  
  7. Install the check valve. Tighten the bolts to 105 inch lbs. (12 Nm).
  8.  
  9. Connect the connector tube to the check valve by pushing the fitting over the check valve.
  10.  
  11. Connect the O 2 S electrical connector.
  12.  
  13. Install the rear engine mount and transaxle bracket.
  14.  
  15. Install the exhaust system. Tighten fasteners to 21 ft. lbs. (28 Nm).
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the negative battery cable.
  20.  

2.7L Engine
Front
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery cable
     
    The cross under pipe
     
    The front catalytic converter
     
    The exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    The exhaust manifold with a new gasket. Torque the bolts, starting in the center and working outward, to 17 ft. lbs. (23 Nm)
     
    The front catalytic converter and heat shield and torque the bolts to 21 ft. lbs. (28 Nm)
     
    The cross under pipe and torque the bolts to 21 ft. lbs. (28 Nm)
     
    The negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

Rear
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery cable
     
    The throttle body air inlet hose
     
    The air cleaner assembly
     
    The Exhaust Gas Recirculation (EGR) tube from the exhaust manifold and EGR valve
     
    The exhaust system
     
    The cross under pipe
     
    The rear catalytic converter
     
    The rear Oxygen Sensor (O 2 S)
     
    The exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    The exhaust manifold with a new gasket. Torque the bolts, starting in the center and working outward, to 17 ft. lbs. (23 Nm)
     
    The rear catalytic converter and heat shield and torque the bolts to 21 ft. lbs. (28 Nm)
     
    The rear O 2 S
     
    The cross under pipe and torque the bolts to 21 ft. lbs. (28 Nm)
     
    The exhaust system
     
    The EGR tube with new gaskets
     
    The air cleaner assembly and air intake hose
     
    The negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
label.common.footer.alt.autozoneLogo