Exhaust Manifold: Service and Repair

EXHAUST MANIFOLD GASKETS- V8
Service repair no - 30.15.16 - Right Hand
Service repair no - 30.15.17 - Left Hand

1. Release 3 fixings and remove battery cover.
2. Disconnect battery negative lead.
3. Raise vehicle on four post lift.





4. Remove 3 nuts securing each front pipe flange to exhaust manifold.
5. Release front pipe from exhaust manifold. Collect gaskets.
6. Lower lift.





7. Disconnect multiplug from MAF sensor and release harness from clip on air intake hose.
8. Release clip and disconnect hose from IAC valve.
9. Loosen clip and disconnect air intake hose from throttle body.
10. Release two clips securing MAF sensor to air cleaner.
11. Remove MAF sensor and hose assembly. Collect O-ring.





12. Release spark plug caps. Release H.T. leads from clips on rocker cover. Place leads aside.
13. RH Manifold Only. Loosen RH shock absorber top mounting bolt (to provide clearance for heat shield removal).

NOTE: Do not remove bolt.

14. RHD, RH Manifold Only. Remove steering column intermediate shaft.





15. Remove 8 (RH exhaust manifold) or 7 (LH exhaust manifold) bolts securing outer heat shield to manifold. Remove heat shield.





16. Remove 8 bolts securing exhaust manifold to cylinder head. Remove exhaust manifold and collect gaskets.


Refit
17. Ensure mating faces are clean.
18. Position manifold on cylinder head. Align new gaskets.





19. Secure manifold with bolts. Tighten to 55 Nm (40 ft. lbs.) in sequence shown.
20. Fit outer heat shield. Secure with bolts. Tighten to 8 Nm (6 ft. lbs.).
21. Fit MAF sensor and hose assembly to throttle body. Secure with clip.
22. Fit O-ring to MAF sensor. Secure MAF sensor to air cleaner with clips.
23. Connect multiplug to MAF sensor. Engage harness in clip on air intake hose.
24. RH Manifold Only. Tighten RH shock absorber top mounting bolt to 85 Nm (63 ft. lbs.).
25. Route H.T. leads. Secure in clips. Connect plug caps.
26. RHD, RH Manifold Only. Fit steering column intermediate shaft.
27. Raise lift.
28. Fit new gasket to front pipe. Position pipe to exhaust manifold. Secure with nuts. Tighten to 50 Nm (37 ft. lbs.).
29. Reconnect battery negative lead.
30. Fit battery cover and secure with fixings.