2.4L DOHC Engine: Manifold-Exhaust: Removal

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

Fig 1: 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

1. Remove clean air hose (1) and air cleaner housing (2).
2. Disconnect negative cable from battery.
   Fig 2: Throttle Cables - 2.4L Turbo

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3. Disconnect throttle and speed control cables from the throttle lever and bracket.
   Fig 3: MAP Sensor

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   1 - MAP SENSOR

4. Disconnect MAP sensor (1) electrical connector.
   Fig 4: Power Steering Fluid Reservoir

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   1 - POWER STEERING FLUID RESERVOIR

   2 - RETAINING TAB

5. Remove fasteners securing power steering fluid reservoir (1) to cylinder head.
6. Remove coolant recovery container (Refer to COOLING/ENGINE/COOLANT RECOVERY CONTAINER - REMOVAL) .
   Fig 5: Exhaust Manifold Heat Shield Bolts

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   1 - BOLTS

7. Remove bolts (1) attaching upper heat shield. See Fig 5.
8. Remove upper heat shield.
9. Raise vehicle.
   Fig 6: Exhaust System To Manifold Connection

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   1 - GASKET

   2 - CATALYTIC CONVERTER

   3 - NUT

10. Disconnect exhaust pipe from manifold. See Fig 6.
    Fig 7: Heat Shield - Engine Wiring

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    1 - HEAT SHIELD

    2 - NUT

    3 - NUT

11. Remove engine wiring heat shield (1). See Fig 7.
    Fig 8: Exhaust Manifold Support Bracket

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12. Remove manifold support bracket. See Fig 8.
    Fig 9: Exhaust Manifold Heat Shields

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    1 - UPPER HEAT SHIELD

    2 - LOWER HEAT SHIELD

13. Remove lower exhaust manifold heat shield (2). See Fig 9.
14. Disconnect oxygen sensor electrical connector.
    Fig 10: Exhaust Manifold - Loosening & Tightening Sequence

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15. Remove exhaust manifold lower retaining fasteners. See Fig 10.
16. Lower vehicle and remove the upper exhaust manifold retaining fasteners.
17. Remove exhaust manifold from above/between the engine and cowl panel.
18. Remove and discard manifold gasket.