How to Replace the Exhaust Manifold in Cars

by Contributing Writer; Updated June 12, 2017

Though you might not have to change the manifolds on both sides of the engine, you should at least change the gasket on the side you are not replacing, unless it has been changed recently. Finding a replacement exhaust manifold might be chore, as this part rarely breaks. If you cannot find it a an auto parts store, check the dealership and the used auto parts yards.

Under The Hood:

 How to Replace the Exhaust Manifold in a Dodge Ram 1500

Chock the rear wheels and set the parking brake on your truck. Position the floor jack under the forward frame rail behind the front wheel and lift the truck one side at a time. Use jack stands to support the truck. From the underside of the truck, remove the bolts and nuts that attach the exhaust pipe to the exhaust manifold. Lower the truck to the ground.

Remove the four nuts from the heat shield and remove the shield. Note which manifold bolt positions have the threaded studs so you can put them back in the same positions during reassembly. Remove the manifold bolts and remove the manifold and manifold gaskets. Discard the gaskets. Inspect the mating surfaces and scrap as needed to make a smooth, clean face for the new gaskets.

Position the exhaust manifold gasket and install the manifold. Tighten the manifold bolts to 18 foot-pounds starting from the center bolts and working out to each end. Install the manifold shield and nuts. Tighten the nuts to 72 inch-pounds and then loosen them 45 degrees.

Lift the truck and support it on jack stands. Install the exhaust pipe gasket and mate the exhaust pipe to the manifold. Install the nuts and bolts and tighten them to 25 foot-pounds. Lower the truck to the ground.

Items you will need

  • Wheel chocks

  • Floor Jack

  • Jack stands

  • Wrench set

  • Ratchet

  • Socket set

  • Scraper

  • Exhaust manifold gasket

  • Torque wrench

  • Exhaust pipe gasket

 How to Replace the Exhaust Manifold in a Pontiac Grand Am

Remove the Exhaust Manifold

Disconnect the negative battery cable. Remove the air cleaner assembly, the throttle body duct and the exhaust crossover heat shield.

Pull the exhaust crossover pipe from the manifold. Disconnect the radiator hose from the thermostat housing.

Label and disconnect the spark plug wires. Take off the exhaust manifold heat shield. Remove the exhaust manifold fasteners and lift the manifold from the engine. Discard the gasket.

Clean the mating surfaces to remove any gasket material, dirt and carbon deposits. Wipe the surfaces with solvent. Check the mating surfaces for damage.

Install the Exhaust Manifold

Install the exhaust manifold with a new gasket. Torque the nuts in sequence to 12 foot pounds in three passes.

Set the exhaust manifold heat shield in place. Torque the nuts to 89 inch pounds. Connect the exhaust crossover pipe. Tighten the bolts to 18 foot pounds.

Place the crossover pipe heat shield in place. Torque the bolts to 89 inch pounds. Reconnect the spark plug wires and the radiator hose.

Reinstall the air cleaner assembly and the throttle body duct. Reconnect the negative battery cable to the terminal.

Start the engine and allow it to run for several minutes. Check for exhaust leaks. Make sure the engine is operating correctly.

 How to Replace the Exhaust Manifold on a 1997 Jeep Wrangler

Disconnect the battery negative cable using pliers to prevent inadvertent airbag deployment.

Prepare the vehicle for the replacement of the exhaust manifold by removing the intake manifold if you have a 2.5L, 4.0L and 4.2 L engine. (Refer to the Resources or other Jeep Wrangler repair books for directions on how to remove and replace the intake manifold.) Also, remove the exhaust gas recirculation, or EGR, tube from the exhaust manifold using a flare-nut wrench (open-ended wrench optional).

Prepare a 2.4L-engine equipped vehicle by using a jack to place the front axle up on jackstands.

Spray the bolts that connect the exhaust manifold to the engine and to the exhaust pipe with penetrating oil. Remove the bolts and nuts that hold the exhaust pipe to the exhaust manifold using socket wrenches.

Lower the front end of the 2.4L-engine equipped vehicle to the ground.

Remove the air filter housing bracket and the exhaust manifold heat shield on a 2.4L engine using socket wrenches.

Disconnect the wiring harness from the oxygen sensor with your hand on a four-cylinder engine. Remove the oxygen sensor using an open-ended wrench.

Remove the bolts (2.4L engine), nuts (2.5L, 4.0L and 4.2L engines), and spacers (2.5L engine) that hold the exhaust manifold to the cylinder head. Remove the exhaust manifold. Remove the exhaust manifold gasket and clean any residue from the mating surface on the cylinder head.

Reinstall the oxygen sensor on the new exhaust manifold (four-cylinder engine) using a new oxygen sensor gasket.

Install the new exhaust manifold on the engine using a new exhaust manifold gasket. Reinstall the attaching hardware and hand tighten the bolts or nuts.

Place a vehicle with a 2.4L engine back up on the jackstands. Connect the exhaust pipe to the exhaust manifold (any engine) and hand tighten the attaching hardware.

Torque the exhaust manifold bolts (2.4L engine) to 200 inch-pounds using a torque wrench. Note: Start at the center and alternate tightening the bolts out to the ends. Torque the exhaust manifold nuts to 23 foot pounds (2.5L, 4.0L and 4.2L engines). Note: Wait until the intake manifold is reinstalled to torque the exhaust manifold nuts. Torque the exhaust manifold to exhaust pipe attaching hardware to 21 foot-pounds (all engines).

Lower the front end of the 2.4L-engine vehicle to the ground.

Reinstall all parts removed during the replacement of the exhaust manifold. Reconnect the battery negative cable. Start the engine and look for exhaust leaks.

Items you will need

  • Pliers

  • Jack

  • Jackstands

  • Flare-nut wrench (open-ended wrench optional)

  • Penetrating oil

  • Socket wrenches

  • Open-ended wrenches

  • Exhaust manifold

  • Oxygen sensor gasket

  • Exhaust manifold gasket

  • Torque wrench

 How to Change an Exhaust Manifold in a Chevrolet Impala 3400

Left Side

Loosen the clamps on the air duct and throttle body inlet duct, using the screwdriver, pliers or a socket, depending on the type of clamp used -- different years may use different types of clamps, or a previous owner may have used a different type of clamp. Remove the air ducts. Remove the air filter and air box, using the appropriate socket.

Remove the right engine mount-strut bracket, exhaust crossover pipe shield and the exhaust crossover pipe nuts on the left manifold, using the appropriate sockets. Remove the exhaust manifold heat shield, using the appropriate socket. Remove the exhaust manifold, using the appropriate wrench to remove the bolts at the engine and the nuts at the collector.

Install the new manifold and new gaskets at the collector and the engine. Torque the bolts to 12 foot-pounds of torque. Reinstall the exhaust manifold heat shield. Torque the bolts to 89 inch-pounds of torque.

Reinstall the crossover pipe and torque the bolts to 18 foot-pounds of torque. Reinstall the crossover pipe heat shield, tightening the bolts to 89 inch-pounds of torque. Install the right engine mount-strut bracket, throttle body air inlet duct and the air cleaner box and its ducts.

Right Side

Remove the throttle body air inlet duct, using the appropriate socket, screwdriver or pliers, depending on the type of clamp on the duct. Unbolt and remove the accelerator cable bracket from the throttle body.

Unplug the manifold air pressure, or MAP, sensor, then remove it, using the appropriate sockets. Unbolt and remove the exhaust manifold recirculation, or EGR, pipe, using the appropriate socket.

Mark the spark plug wires with the tape and marker. Pull them off the spark plugs. Unplug the wiring harness connectors on the ignition module and the ignition coils. Unbolt and remove the module and coils. Unplug the oxygen sensor wiring harness connector.

Remove the evaporative emissions, or EVAP, solenoid bracket. Remove the exhaust crossover heat shield, using the appropriate socket. Remove the exhaust crossover pipe from the manifold, using the appropriate socket or wrench.

Unbolt the catalytic converter from the manifold, then remove the exhaust manifold heat shields, using the appropriate sockets and wrenches. Unbolt the exhaust manifold from the engine, then remove the manifold.

Install the new manifold with a new gasket, tightening the bolts to 12 foot-pounds of torque. Reinstall the exhaust manifold heat shields and tighten the bolts to 89 inch-pounds of torque. Reinstall the catalytic converter, tightening the bolts to 24 foot-pounds of torque.

Reinstall the crossover pipe and tighten the bolts to 18 foot-pounds of torque. Reinstall the crossover pipe heat shield, tightening the bolts to 89 inch-pounds of torque. Reinstall the EVAP solenoid bracket and the oxygen sensor connector.

Reattach the spark plug wires, ensuring that you put them on the proper plugs, and that the wires snap onto the plugs. Reinstall the module, coils and the bracket. Reinstall the EGR pipe and tighten the bolts firmly. Reinstall the MAP sensor and plug it in. Reattach the accelerator cable onto the throttle body. Reinstall the throttle body air inlet duct.

Items you will need

  • Screwdriver

  • Pliers

  • Set of sockets

  • Set of wrenches

  • Torque wrench (foot-pounds)

  • Torque wrench (inch-pounds)

  • Tape and marker

 How to Replace the Exhaust Manifold in a 5.7

Jack the vehicle up with the floor jack and support it with jack stands. Unbolt the exhaust system from the manifold collectors. Remove bolts from the manifold where it bolts up to the head. Pull the exhaust manifold out of the vehicle. Repeat for the other side.

Slide the new exhaust manifold into place. Insert the gasket between the head and the manifold. Screw in the bolt closest to the firewall for two or three threads. Screw the very front bolt in two or three threads. Insert the rest of the bolts. Tighten snugly. If you are installing headers, do the same thing, except slide a lock washer onto the bolt before inserting the bolts. Repeat for the other side.

Slide under the car. Line the exhaust system up to the manifold collector. Insert the manifold collector gasket, then the collector bolts. Tighten the bolts. Repeat for the other side.

Items you will need

  • Floor jack

  • Jack stands

  • Set of wrenches

  • Set of sockets

 How to Replace the Exhaust Manifold on a 2002-2005 Chevy Trailblazer EXT 4.2L

Removing the Exhaust Manifold

Drive your Trailblazer on the highway for about 20 minutes to raise the engine and exhaust manifold temperatures. This will help when you remove the oxygen sensor from the exhaust manifold.

Return home and open the hood. Locate the oxygen sensor, which is above the exhaust manifold flange where it joins the front exhaust pipe that contains the catalytic converter. The sensor has a cylindrical body, about the size of a spark plug, with an electrical wire on the end. Unplug the sensor's electrical connector.

Unfasten and remove the oxygen sensor with a J 39194-C oxygen sensor wrench and ratchet on the 2002 and 2003 Trailblazer models; use the J 39194-B oxygen sensor wrench and a ratchet on the 2004 and 2005 Trailblazer models. Keep the sensor in a safe place so that dirt and grease do not come in contact with the tip and electrical connector.

Unfasten the front exhaust pipe, which contains the catalytic converter, from the exhaust manifold with a breaker bar and socket. If necessary, use penetrating oil on the mounting bolts.

Block the rear wheels with wood blocks and set the parking brake.

Raise the front of your Trailblazer with a floor jack and support with a jack stand on each side.

Put on your goggles, get under the SUV and disconnect the rear of the front exhaust pipe from the exhaust system with a breaker bar and socket. Detach the front exhaust pipe hook from the rubber hanger using a standard screwdriver as a pry tool.

Lower your Trailblazer off the jack stands with the floor jack.

Remove the heat shield from the top of the exhaust manifold with a ratchet and socket. With the help of an assistant, unfasten the exhaust manifold mounting bolts with a ratchet, short ratchet extension and socket, and remove the manifold and gasket from the engine.

Installing the New Exhaust Manifold

Position the new exhaust manifold in place along with a new gasket with the help of an assistant. Coat the threads of the mounting bolts with the threadlock and hand-tighten the bolts.

Tighten the exhaust manifold mounting bolts to 15 foot-lbs. with a torque wrench and socket. Start with the bolt on the center of the manifold and then proceed with the one on the left and then the one on the right. Follow this alternating sequence until you torque all the bolts.

Torque the exhaust manifold bolts two more times following the same sequence to ensure all the bolts are properly installed. Reattach the heat shield.

Raise your Trailblazer with the floor jack and install the jack stands.

Put on your goggles and connect the rear of the front exhaust pipe to the exhaust system with the breaker bar and socket and insert the pipe hook into the rubber hanger.

Lower your Trailblazer and remove the wood blocks from behind the rear wheels.

Connect the front exhaust pipe to the exhaust manifold with the breaker bar and socket.

Coat the threads of the oxygen sensor with antiseize compound and install the sensor hand tight. Tighten the sensor on the 2002 and 2003 Trailblazer models with the J 39194-C oxygen sensor wrench and ratchet. Use the J 39194-B on the 2004 and 2005 Trailblazer models.

Plug in the oxygen sensor electrical connector and close the hood.

Items you will need

  • J 39194-C oxygen sensor wrench for 2002 and 2003 Trailblazer models

  • J 39194-B oxygen sensor wrench for 2004 and 2005 Trailblazer models

  • Breaker bar

  • Socket set

  • Penetrating oil

  • 2 wood blocks

  • Floor jack

  • 2 jack stands

  • Goggles

  • Standard screwdriver

  • Assistant

  • Ratchet

  • Short ratchet extension

  • Threadlock (GM part number 12345493)

  • Torque wrench

  • Antiseize compound

 How to Change the Exhaust Manifold on a Nissan Xterra 2000

Removal

Disconnect the Xterra's negative battery cable.

Raise the front end of the truck and support it on jack stands. Block the rear wheels with wheel chocks or large blocks.

Remove the engine splash shields if the Xterra is equipped with them by removing their bolts with a wrench.

Remove the three nuts connecting the exhaust pipe from the manifold to disconnect the two components.

Unscrew and remove the air intake duct with the air cleaner's top half from the throttle body, then unscrew and remove the bracket for the oil dipstick from the manifold. This is required only for the left manifold on a V6 engine.

Disconnect the lower heat shield from the exhaust manifold, which is in the engine compartment. It has four nuts. Disconnect the oxygen sensor's electrical connector, then remove the upper heat shield by removing its seven nuts.

Unbolt and disconnect the EGR pipe from the manifold.

Remove the mounting nuts connecting the manifold to the cylinder head; remove the ones on the outer edges first and work your way to the middle of the manifold. Detach and remove the manifold with its gaskets.

Installation

Scrape away all traces of gasket material and carbon deposits from the cylinder head mating surface, and make sure no such material is on the replacement exhaust manifold. Place new gaskets on the studs on the cylinder heads.

Install the new exhaust manifold in place on the cylinder heads and thread the mounting nuts onto the studs by hand. Tighten the nuts with the wrench, starting with the middle nuts and working your way outward.

Reconnect the other parts--the EGR pipe, the upper and lower heat shields for the manifold, the oxygen sensor's electrical connector, the exhaust pipe and the splash shields. Apply an anti-seize compound to the exhaust pipe's studs and the EGR pipe's nut when connecting these component.

Lower the truck off the jack stands and reconnect the battery cable.

Items you will need

  • Floor jack

  • Jack stands

  • Wheel blocks

  • Wrench

  • Scraper

  • Exhaust manifold gaskets

  • Anti-seize compound

 How to Replace the Exhaust Manifold in a Honda CR-V

Remove the Exhaust Manifold

Take the negative battery cable from the terminal. Raise the front of the vehicle on jackstands. Make sure the supports are secure.

Unbolt the splash shield from under the engine and remove it. Remove the oxygen sensor electrical connectors (on D17A1 and D17A6 engines).

Apply penetrating to the fastener threads of the exhaust pipe and the heat shield. Allow it to soak in for several minutes. Unbolt the exhaust pipe from the manifold. Remove the heat shield.

Remove the exhaust manifold bracket, then loosen and remove the exhaust manifold nuts. Take the exhaust manifold from the cylinder head.

Pull out the gaskets and discard them. Use a scraper to remove any gasket debris and carbon deposits.

Install the Exhaust Manifold

Clean the exhaust manifold and cylinder head mating surfaces with solvent. Examine the surfaces for damage.

Set the new gasket in place and position the exhaust manifold on the cylinder head. Put the nuts in place and finger-tighten them.

Start at the center and work out towards the ends to tighten the nuts. Make three passes to torque the nuts to 23 foot pounds.

Use new upper bolts to install the heat shield. Torque the two upper bolts to 23 foot pounds. Tighten the other heat shield bolts securely.

Connect the exhaust pipe to the exhaust manifold with new bolts. Torque the bolts to 16 foot pounds.

Reconnect the other components in the reverse order of their removal. Connect the negative cable to the battery terminal.

Start the engine and allow it to warm up. Check for exhaust leaks between the exhaust manifold and head and between the exhaust manifold and the exhaust pipe.

 How to Replace the Exhaust Manifold in a Toyota Tundra

Remove the Exhaust Manifold

Take the negative cable from the battery terminal. Coat the exhaust manifold fasteners with penetrating oil and let is soak in for several minutes.

Remove the exhaust crossover pipe from the rear of the cylinder heads. Remove the EGR pipe from the manifold, then loose and remove the bolts that hold the exhaust manifold to the cylinder heads.

Inspect the manifolds and the fasteners for damage or cracks. Replace them as needed.

Scrape all the old gasket material from the manifold and cylinder mating surfaces. Use a solvent and compressed air as necessary to remove all carbon deposits.

Install the Exhaust Manifold

Place the new gaskets over the studs on the cylinder heads. Align the exhaust manifolds over the new gaskets.

Set the mounting nuts in place and finger-tighten them. Tighten the nuts in sequence, working out from the center. Make three or fours passes over the nuts to torque them to 30 foot pounds.

Reinstall the components in reverse order of their removal. Reconnect the exhaust pipes with new gaskets.

Reconnect the negative battery cable to the terminal. Start the engine. Check for exhaust leaks.

 How to Replace the Exhaust Manifold in a Mazda6

Remove the Exhaust Manifold

Take the negative battery cable from the terminal. Remove the main silencer and pre-silencer, then remove the three-way converter from the side on which the manifold is being replaced.

Remove the stud bolt and the front pipe. Unplug the two heated oxygen sensor connectors, then take out the exhaust gas recirculation (EGR) pipe.

Loosen and remove the exhaust manifold fasteners. Lift the exhaust manifold from the engine and discard the gasket.

Scrape the mating surfaces to remove any gasket material, dirt and carbon deposits. Wipe the surfaces with solvent. Check for damage.

Install the Exhaust Manifold

Install the new gasket to the cylinder head. Position the V over the gasket.

Tighten the exhaust manifold fasteners in sequence, workout out from the center. Torque the bolts to 14 to 19 foot pounds.

Reconnect the EGR tube and the two heated oxygen sensor connectors. Connect the front pipe with a new gasket.

Replace the three-way converter and then reconnect the pre-silencer and the main silencer. Attach the negative battery cable to the terminal and secure it.

Start the engine and allow it to run for several minutes. Check for exhaust leaks and proper engine operation.

 How to Replace the Exhaust Manifold in a Plymouth Neon

Remove the Exhaust Manifold

Disconnect the negative battery cable and take out the wiring harness heat shield-to-exhaust manifold support bracket. Remove the exhaust manifold support bracket bolt and then the bracket.

Take out the exhaust flex joint-to-manifold flange fasteners. Push the exhaust system to the rear to clear the flange studs.

Remove the make-up air hose, the speed control vacuum reservoir, the oxygen sensor connector and harness clip. Disconnect the upper heat shield.

Loosen and remove the bolts to the exhaust manifold. Lift the exhaust manifold from the engine and discard the gasket.

Scrape the mating surfaces to remove any gasket material, dirt and carbon deposits. Wipe the surfaces with solvent. Check for damage.

Install the Exhaust Manifold

Install the exhaust manifold with the new gasket. Torque the nuts in sequence working out from the center to 16 foot pounds.

Place the upper and lower heat shields in position and torque to 95 inch pounds. Install the oxygen sensor connector and the harness clip. Replace the cylinder head cover, the speed control vacuum reservoir and the make-up air hose.

Set the cylinder head-to-exhaust manifold support bracket in place. Torque the bolts to 40 foot pounds.

Connect the wiring harness heat shield-to-exhaust manifold. Replace the support bracket bolt.

Reconnect the negative battery cable. Turn on the engine and allow it to run for several minutes. Check for exhaust leaks and proper engine operation.

 How to Replace the Exhaust Manifold in a Ford Mustang

Remove the Exhaust Manifold

Pull the negative batter cable from the terminal. Remove the secondary air injection hardware, the air cleaner and the inlet duct.

Label and disconnect the spark plug wires. Pull the spark plugs from the cylinders heads. Take the oil dipstick tube from the exhaust manifold stud.

Disconnect the exhaust pipes and the oxygen sensor connector.

Remove the bolts and washers from the exhaust manifold. Remove the manifold.

Install the Exhaust Manifold

Clean all the gasket mating surfaces with compressed air and solvent. Examine the surfaces thoroughly for damage.

Place a new gasket on the manifold and set the manifold to the cylinder head. Set the mounting bolts in place and finger-tighten them. Replace the oil dipstick tube and the oxygen sensor, then engage the connector.

Put the exhaust pipes in place. Tighten the flange nuts to 20 to 30 foot pounds.

Install the spark plug and then connect the wires. Replace the air injection hardware, the air cleaner and the inlet duct.

Reconnect the negative batter cable. Start the engine. Check the system for exhaust leaks.

 How to Replace the Exhaust Manifold in a VW Beetle

Remove the Exhaust Manifold

Take off the engine cover, then remove the air intake duct and the cowl cover. Lift out the upper intake manifold and then remove the hoses from the air injection control valve.

Use jack stands to lift the front of the vehicle. Make sure the supports are secure.

Locate the oxygen sensor electrical connectors and disconnect them. Pull the wiring harness form the oxygen sensor from the manifold retaining bracket.

Treat the exhaust manifold mounting bolts and nuts with penetrating oil. Disconnect the exhaust pipe from the manifold then take out the front exhaust pipe. Remove the support brace.

Loosen the air injection pipe union nuts on the manifold and remove them. Disconnect the air injection control valve.

Identify the warm air deflector plate and remove it from the engine. Remove the bolts and take out the manifold and gasket.

Install the Exhaust Manifold

Scrape the old gasket material and debris from the mating surfaces. Check the gasket for damage and warping.

Set a new gasket into place over the cylinder head studs. Install the manifold and put the nuts over the bolts. Use a high temperature anti-seize compound on the fasteners.

Tighten the bolts in sequence, working from the center out and in a criss-cross pattern. Make three or four passes to torque the bolts to 18 foot pounds.

Reinstall and reconnect the remaining parts in the reverse order of their removal. Turn on the engine and check for exhaust leaks.

About the Author

This article was written by the It Still Runs team, copy edited and fact checked through a multi-point auditing system, in efforts to ensure our readers only receive the best information. To submit your questions or ideas, or to simply learn more about It Still Runs, contact us.