Exhaust Manifold Replacement

REMOVAL PROCEDURE

CAUTION:
^ In order to avoid being burned, do not service the exhaust system walls while it is still hot. Service the system when it is cool.
^ Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Disconnect the Heated Oxygen Sensor (H02S1) electrical connector.
3. Remove the air intake pipe from ACL intake hose and throttle hose.
4. Remove three bolts and air intake pipe bracket from the cylinder head.





5. Remove the following from the exhaust manifold (2):
^ Two nuts
^ Three bolts
^ The upper exhaust manifold heat shield (3)

6. Raise and suitably support the vehicle.





7. Remove the following from the exhaust manifold and engine block:
^ Three bolts
^ One nut
^ The exhaust manifold reinforcement bracket (1)





8. Remove the following from the exhaust manifold (1):
^ Two bolts
^ The front pipe/Three Way Catalytic Converter (TWO) assembly (3) with the gasket (2)

9. Lower the vehicle.





10. Remove the nine nuts (1) from the exhaust manifold.





11. Remove the exhaust manifold (2) with the gasket (1) from the engine hanger.





12. Remove the engine hanger (3) from the cylinder head.





13. Remove the two bolts and lower the exhaust manifold heat shield (6) from the exhaust manifold (2).
14. Remove the Heated Oxygen (H02S1) Sensor (4) from the exhaust manifold (2).

INSTALLATION PROCEDURE

NOTICE: Refer to Fastener Notice in Service Precautions.

1. Install the Heated Oxygen (H02S1) Sensor into the exhaust manifold.
^ Tighten the (H02S1) Sensor to 43 Nm (32 ft. lbs.).





2. Install the new exhaust manifold gasket (1) and the exhaust manifold (2) with the engine hanger.





3. Install the engine hanger (3) to the cylinder head. Secure the hanger with nine nuts (1).
4. Raise and support the vehicle.





5. Install the front pipe/TWC assembly (3) with a new gasket (2) to the exhaust manifold (1). Secure the assembly with three bolts.
^ Tighten the exhaust manifold-to-front pipe/TWC assembly bolts to 50 Nm (37 ft. lbs.).





6. Install the lower exhaust manifold heat shield (6) to the exhaust manifold (2). Secure the heat shield with two bolts.
^ Tighten the lower exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.).





7. Install the exhaust manifold brackets (1) to the exhaust manifold and the engine block. Secure the brackets with one nut and two bolts.
^ Tighten the engine mount-to-exhaust bracket bolts to 54 Nm (40 ft. lbs.).
^ Install the exhaust bracket-to-exhaust manifold nut to 50 Nm (37 ft. lbs.).

8. Lower the vehicle.





9. Install the upper exhaust manifold heat shield (3) to the exhaust manifold (2). Secure the heat shield with two nuts and three bolts.
^ Tighten the upper exhaust manifold heat shield nuts and bolts to 10 Nm (89 inch lbs.).

10. Install the air intake pipe bracket to the cylinder head. Secure the bracket with three bolts.
^ Tighten the air intake pipe bracket bolts to 10 Nm (89 inch lbs.).

11. Install the air intake pipe to the throttle body hose and ACL intake hose.
12. Connect the (HO2S1) electrical connector.
13. Connect the negative battery cable.