Vue 2002-2005

Exhaust Manifold

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Exhaust manifold heat shield
     
    Oxygen (O 2 S) sensor from the manifold
     
    Exhaust pipe from the manifold
     
    Exhaust pipe-to-resonator pipe nuts from behind the converter
     
    Exhaust manifold pipe and resonator pipe
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Remove the exhaust manifold and gasket-2.2L engine

     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts, starting from the center and working outward, to 13 ft. lbs. (18 Nm)
     
    O 2 S sensor and torque it to 33 ft. lbs. (45 Nm)
     
    Exhaust pipe to the manifold with a new gasket and torque the nuts to 22 ft. lbs. (30 Nm)
     
    Exhaust pipe-to-resonator pipe nuts and tighten to 31 ft. lbs. (42 NM)
     
    Exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    air cleaner assembly
     
    Negative battery cable
     

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

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

    The negative battery cable
     
    The air cleaner assembly
     
    The exhaust manifold heat shield
     
    The Oxygen (O 2 S) sensor from the manifold
     
    The exhaust pipe from the manifold
     
    The exhaust pipe-to-resonator pipe nuts from behind the converter
     
    The exhaust manifold pipe and resonator pipe
     
    The exhaust manifold

    Click image to see an enlarged view

    Fig. Remove the exhaust manifold and gasket-2.2L engine

     

  4.  

To install:

  1. Install or connect the following:

    The exhaust manifold with a new gasket and torque the bolts, starting from the center and working outward, to 13 ft. lbs. (18 Nm)
     
    The O 2 S sensor and torque it to 33 ft. lbs. (45 Nm)
     
    The exhaust pipe to the manifold with a new gasket and torque the nuts to 22 ft. lbs. (30 Nm)
     
    The exhaust pipe-to-resonator pipe nuts and tighten to 31 ft. lbs. (42 Nm)
     
    The exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    The air cleaner assembly
     
    The negative battery cable
     

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

2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the exhaust manifold heat shield.
  4.  
  5. Remove the Heated Oxygen Sensor (HO2S).
  6.  
  7. Remove the exhaust manifold pipe.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the upper exhaust manifold brace bolt.
  12.  
  13. Remove and discard the exhaust manifold nuts.
  14.  
  15. Remove the exhaust manifold/catalytic converter assembly.
  16.  
  17. Remove and discard the exhaust manifold gasket.
  18.  

To install:

  1. Install a NEW exhaust manifold gasket onto the manifold studs.
  2.  
  3. Install the exhaust manifold/catalytic converter assembly.
  4.  
  5. Install the NEW exhaust manifold nuts finger tight.
  6.  
  7. Install the upper exhaust manifold brace bolt to 43 ft. lbs. (58 Nm).
  8.  
  9. Tighten the manifold bolts in the sequence shown to 10 ft. lbs. (14 Nm).
  10.  
  11. Raise and suitably support the vehicle.
  12.  
  13. Install the exhaust manifold pipe.
  14.  
  15. Install the HO2S.
  16.  
  17. Install the exhaust manifold heat shield.

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-2.4L engine

  18.  

3.0L Engine
Front Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold Oxygen (O 2 S) sensor
     
    Coolant extension pipe and engine lift bracket bolts
     
    Oil level indicator tube
     
    Upper exhaust manifold nuts
     
    Front down pipe assembly
     
    Right hand splash shield
     
    Accessory drive belt
     
    A/C compressor and pressure transducer connections
     
    A/C compressor-to-bracket bolts and position the compressor aside without disconnecting the lines
     
    Lower exhaust manifold nuts
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Front down pipe and gaskets
     
    A/C compressor and tighten the bolts to 16 ft. lbs. (22 Nm)
     
    Electrical connections to the pressure transducer and compressor
     
    Accessory drive belt
     
    Right hand splash shield
     
    Oil level indicator tube
     
    Coolant extension pipe/engine lift bracket bolt and torque to 15 ft. lbs. (20 Nm)
     
    O 2 S sensor, tighten to 33 ft. lbs. (45 Nm) and attach the electrical connection
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

Rear Manifold
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Purge solenoid from the manifold
     
    Middle exhaust manifold nut using a boxed end wrench
     
    Oxygen (O 2 S) sensor connection at the rear of the engine
     
    Rear exhaust manifold pipe
     
    Right hand stabilizer bar-to-frame bolts
     
    Left-to-right hand stabilizer bar to lower link nut and discard the nut
     
    Exhaust manifold pipe heat shield
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Manifold heat shield and tighten the retainers to 18 ft. lbs. (25 Nm)
     
    Right hand stabilizer bar-to-frame bolts and tighten to 37 ft. lbs. (50 Nm)
     
    New left-to-right hand stabilizer bar to lower link nut to 48 ft. lbs. (65 Nm)
     
    Rear exhaust manifold pipe
     
    O 2 S sensor connection at the rear of the engine
     
    Middle exhaust manifold nut using a boxed end wrench to 15 ft. lbs. (20 Nm)
     
    Purge solenoid to the manifold
     
    Air cleaner assembly
     
    Negative battery cable
     

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

3.5L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the Intake Air Temperature (IAT) sensor connector.
  4.  
  5. Loosen the clasp at the air cleaner assembly.
  6.  
  7. Remove the push-pin attachment from the outlet resonator/duct assembly to support the bracket.
  8.  
  9. Loosen the clamp at the throttle body assembly.
  10.  
  11. Disconnect the Positive Crankcase Ventilation (PCV) hose at the cam cover.
  12.  
  13. Remove the outlet resonator/duct assembly.
  14.  
  15. Remove the exhaust manifold heat shield bolts.
  16.  
  17. Remove the exhaust manifold heat shield.
  18.  
  19. Disconnect the front and rear Oxygen (O 2 S) sensor connectors.
  20.  
  21. Remove the O 2 S sensor if the exhaust manifold is being replaced.
  22.  
  23. Remove the exhaust manifold pipe-to-manifold nuts.
  24.  
  25. Remove the exhaust manifold pipe-to-resonator pipe nuts behind the converter.
  26.  
  27. Disconnect the rear O 2 S sensor wire from the heat shield.
  28.  
  29. Separate the exhaust manifold pipe and resonator pipe and discard the gaskets.
  30.  
  31. Remove the exhaust manifold nuts.
  32.  
  33. Remove the exhaust manifold assembly and discard the gasket.
  34.  

To install:

  1. Install a new manifold gasket on the cylinder head.
  2.  
  3. Install the exhaust manifold and torque the nuts to 13 ft. lbs. (18 Nm).
  4.  
  5. If necessary, transfer the O 2 S sensor from the old manifold.
    NOTE
    Whenever the oxygen sensor is removed, coat the threads with a nickel-based anti-seize.

  6.  
  7. Install the O2 O 2 S sensor into the exhaust manifold and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the gasket and exhaust pipe to the intermediate pipe and tighten the nuts to 22 ft. lbs. (30 Nm).
  10.  
  11. Attach the rear O 2 S sensor wire to the heat shield.
  12.  
  13. Install a new exhaust manifold gasket onto the exhaust manifold flange studs.
  14.  
  15. Attach the exhaust manifold pipe to the exhaust manifold studs and install the exhaust manifold nuts. Tighten the nuts to 31 ft. lbs. (42 Nm).
  16.  
  17. Install the exhaust manifold heat shield and tighten the bolts to 17 ft. lbs. (23 Nm).
  18.  
  19. Install the outlet resonator/duct assembly.
  20.  
  21. Connect the PVC fresh air vent hose.
  22.  
  23. Tighten the clamp at the throttle body assembly.
  24.  
  25. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
  26.  
  27. Tighten the air cleaner assembly.
  28.  
  29. Connect the IAT sensor connector.
  30.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the Intake Air Temperature (IAT) sensor connector.
  4.  
  5. Loosen the clasp at the air cleaner assembly.
  6.  
  7. Remove the push-pin attachment from the outlet resonator/duct assembly to support the bracket.
  8.  
  9. Loosen the clamp at the throttle body assembly.
  10.  
  11. Disconnect the Positive Crankcase Ventilation (PCV) hose at the cam cover.
  12.  
  13. Remove the outlet resonator/duct assembly.
  14.  
  15. Remove the exhaust manifold heat shield bolts.
  16.  
  17. Remove the exhaust manifold heat shield.
  18.  
  19. Disconnect the front and rear Oxygen (O 2 S) sensor connectors.
  20.  
  21. Remove the O 2 S sensor if the exhaust manifold is being replaced.
  22.  
  23. Remove the exhaust manifold pipe-to-manifold nuts.
  24.  
  25. Remove the exhaust manifold pipe-to-resonator pipe nuts behind the converter.
  26.  
  27. Disconnect the rear O 2 S sensor wire from the heat shield.
  28.  
  29. Separate the exhaust manifold pipe and resonator pipe and discard the gaskets.
  30.  
  31. Remove the exhaust manifold nuts.
  32.  
  33. Remove the exhaust manifold assembly and discard the gasket.
  34.  

To install:

  1. Install a new manifold gasket on the cylinder head.
  2.  
  3. Install the exhaust manifold and torque the nuts to 13 ft. lbs. (18 Nm).
  4.  
  5. If necessary, transfer the O 2 S sensor from the old manifold.
    NOTE
    Whenever the oxygen sensor is removed, coat the threads with a nickel-based anti-seize.

  6.  
  7. Install the O2 O 2 S sensor into the exhaust manifold and tighten to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the gasket and exhaust pipe to the intermediate pipe and tighten the nuts to 22 ft. lbs. (30 Nm).
  10.  
  11. Attach the rear O 2 S sensor wire to the heat shield.
  12.  
  13. Install a new exhaust manifold gasket onto the exhaust manifold flange studs.
  14.  
  15. Attach the exhaust manifold pipe to the exhaust manifold studs and install the exhaust manifold nuts. Tighten the nuts to 31 ft. lbs. (42 Nm).
  16.  
  17. Install the exhaust manifold heat shield and tighten the bolts to 17 ft. lbs. (23 Nm).
  18.  
  19. Install the outlet resonator/duct assembly.
  20.  
  21. Connect the PVC fresh air vent hose.
  22.  
  23. Tighten the clamp at the throttle body assembly.
  24.  
  25. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
  26.  
  27. Tighten the air cleaner assembly.
  28.  
  29. Connect the IAT sensor connector.
  30.  

 
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