QuestionI need to weld a broken pipe intersecting the collector. What gaskets do I need and what do I have to watch out for in the removal of the manifold? What are the torque specs for the reinstallation of the exhaust manifold?
Answerexhaust gasket and possible the flange to where it goes to the rest of the pipe.
INSTALLATION
Clean the mating surfaces of the cylinder head and the manifold(s) If the manifold is being replaced, ensure that all the fittings, etc. are transferred to the replacement manifold.
Install a new exhaust/intake manifold gasket over the alignment dowels on the cylinder head.
Position the engine exhaust manifold to the cylinder head. Install fastener No.3 and finger tighten at this time Intake/Engine Exhaust Manifold Installation - 4.0L Engine
Install intake manifold on the cylinder head dowels.
Install washers and fasteners Nos. 1, 2, 4, 5, 8, 9, 10 and 11 Intake/Engine Exhaust Manifold Installation - 4.0L Engine
Install washers and fasteners Nos. 6 and 7 Intake/Engine Exhaust Manifold Installation - 4.0L Engine
Tighten the fasteners in sequence and to the specified torque Intake/Engine Exhaust Manifold Installation - 4.0L Engine
Fasteners Nos. 1 through 5 - Tighten to 33 N·m (24 ft. lbs.) torque.
Fasteners Nos. 6 and 7 - Tighten to 31 N·m (23 ft. lbs.) torque.
Fasteners Nos. 8 through 11 - Tighten to 33 N·m (24 ft. lbs.) torque.
Install the power steering pump and bracket to the intake manifold and water pump. Torque the power steering pump/bracket to manifold bolts to 28 N·m (21 ft. lbs.) Torque the power steering pump bracket to water pump bolts to 47 N·m (35 ft. lbs.)
Install accessory drive belt and tighten to specification. (Refer to group 7, Cooling for correct procedure)
Before connecting the fuel line to the fuel rail, inspect the fuel line O-rings and replace them if necessary. Connect the fuel supply line to the fuel rail assembly. (Refer to Group 14, Fuel System for the correct procedure)
Connect all sensor electrical connections on the intake manifold.
Map Sensor
Idle Air Control Motor
Intake Manifold Air Temperature Sensor
Throttle Position Sensor
Oxygen Sensor Connector
Fuel Injector Connectors
Connect the power brake booster and HVAC vacuum supply hoses.
Connect the canister purge vacuum supply hose to the manifold.
Install the throttle cable, cruise control cable (if equipped), and transmission line pressure (if equipped) cables into the bracket. Connect the cables to the throttle body.
Connect air inlet hose to the throttle body and air cleaner housing.
Raise vehicle on hoist.
Using a new seal, connect the exhaust pipe to the engine exhaust manifold. Tighten the bolts to 31 N·m (23 ft. lbs.) torque.
Lower the vehicle.
Connect the battery negative cable.
Start the engine and check for le
