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Exhaust Manifold: Installation

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

There are two different exhaust manifolds that are used on the 2.4L engine. The PZEV manifold has a check valve attached to it. Each manifold has a different torque sequence that must be followed.

  1. Install new exhaust manifold gasket. DO NOT APPLY SEALER  .
  2. Position exhaust manifold in place. Tighten fasteners in sequence shown in Fig 1 for non-PZEV engines to 23 N.m (200 in. lbs.). For PZEV engines tighten bolts to 23 N.m (200 in. lbs.). Repeat this procedure until all fasteners are at specified torque. See Fig 2.
    Fig 1: Exhaust Manifold Tightening Sequence-Typical
    GC0032129Courtesy of DAIMLERCHRYSLER CORP.
    Fig 2: PZEV Exhaust Manifold Tightening Sequence
    GC0032130Courtesy of DAIMLERCHRYSLER CORP.
  3. Install exhaust manifold heat shield.
  4. Install check valve tighten bolts to 12 N.m (105 in. lbs.) (if equipped).
  5. Connect connector tube to check valve by pushing fitting over check valve.
  6. Connect oxygen sensor electrical connector.
  7. Install rear engine mount and transaxle bracket.
  8. Install exhaust system (Refer to EXHAUST SYSTEM - INSTALLATION) . Tighten fasteners to 28 N.m (250 in. lbs.).
  9. Lower vehicle.
  10. Connect negative battery cable.
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