2.4L DOHC Engine: Manifold-Exhaust: Installation

NOTE: The exhaust manifold on Turbocharged equipped vehicles is serviced as an assembly with the Turbocharger. (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSTALLATION) .

Fig 1: Exhaust Manifold - Loosening & Tightening Sequence

Courtesy of DAIMLERCHRYSLER CORP.

1. Install a new exhaust manifold gasket. DO NOT APPLY SEALER  .
2. Position exhaust manifold in place. Tighten fasteners in the sequence shown above to 23 N.m (200 in. lbs.). See Fig 1. Raise and lower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque.
   Fig 2: Exhaust Manifold Heat Shields

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   1 - UPPER HEAT SHIELD

   2 - LOWER HEAT SHIELD

3. Install exhaust manifold heat shields. See Fig 2. Tighten bolts to 12 N.m (105 in. lbs.).
   Fig 3: Exhaust Manifold Support Bracket

   Courtesy of DAIMLERCHRYSLER CORP.
4. Install exhaust manifold support bracket. See Fig 3.
5. Install engine wiring heat shield. See Figure.
6. Connect oxygen sensor electrical connector.
   Fig 4: Exhaust Manifold To Pipe Connection

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   1 - GASKET

   2 - CATALYTIC CONVERTER

   3 - NUT

7. Install exhaust pipe (2) to manifold with a new gasket (1). See Fig 4. Tighten fasteners to 28 N.m (250 in. lbs.).
8. Install coolant recovery container (Refer to COOLING/ENGINE/COOLANT RECOVERY CONTAINER - INSTALLATION) .
   Fig 5: Power Steering Fluid Reservoir

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   1 - POWER STEERING FLUID RESERVOIR

   2 - RETAINING TAB

9. Install fasteners securing power steering fluid reservoir (1) to cylinder head.
   Fig 6: MAP Sensor

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   1 - MAP SENSOR

10. Connect MAP sensor (1) electrical connector.
    Fig 7: Throttle Cables - 2.4L Turbo

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11. Connect throttle and speed control cables to the throttle lever and bracket.
    Fig 8: Air Inlet System - 2.4L Turbo

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    1 - CLEAN AIR HOSE

    2 - AIR CLEANER HOUSING

    3 - FRESH AIR INLET DUCT

    4 - PDC MOUNTING BRACKET

12. Connect negative cable to battery.
13. Install clean air hose (1) and air cleaner housing (2).