Exhaust Crossover Pipe: Service and Repair

Removal Procedure





1. Remove the transaxle assembly.
2. Remove the two bolts at the left side exhaust manifold (3).

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

3. Disconnect the EGR inlet pipe from the exhaust crossover.
4. Remove the exhaust front pipe. Refer to Front Pipe Replacement.





5. Remove the bolt (1) securing the crossover pipe (2) to the crankcase.
6. Remove the nut securing the ignition module ground wire to the cylinder head.
7. Remove the bolt (3) securing the crossover pipe (2) to the cylinder head.
8. Remove the crossover pipe.

Installation Procedure
1. Install the two flange seals to the crossover pipe.
2. Position the crossover pipe, securely leaving the LH exhaust manifold joint loose.

Notice: Refer to Fastener Notice in Service Precautions.





3. Hand tighten the support bolts (1,3).
4. Install the exhaust front pipe. Refer to Front Pipe Replacement.
^ Tighten the cylinder head support bolt (3) to 25 Nm (18 ft. lbs.).
^ Tighten the crankcase support bolt (1) to 25 Nm (18 ft. lbs.).

5. Install the nut securing the ignition module ground wire to the cylinder head.
Tighten the nut to 17 Nm (13 ft. lbs.).





6. Tighten the fasteners installed in step 2 as follows
Tighten the left hand exhaust manifold (3) bolts to 25 Nm (18 ft. lbs.).

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

7. Hand start the EGR inlet pipe-to-crossover pipe nut to prevent crossthreading.
Tighten the EGR inlet pipe nut to 60 Nm (44 ft. lbs.).
8. Install the transaxle assembly.