Exhaust Manifold Replacement
NOTE:^ For all vehicles with more than 50,000 miles, replace the exhaust manifold. (Replacement of the exhaust manifold includes removal of the exhaust manifold stay.)
^ For vehicles with less than 50,000 miles; only replace the exhaust manifold if a leak in the exhaust manifold is found during the leak check.
1. Write down the radio station presets.
2. If equipped, write down the customer settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed).
3. Disconnect the negative battery cable.
4. Raise the vehicle on a hoist.
5. WARNING: Wait for the exhaust system to cool before touching exhaust system components. Hot exhaust components can cause severe burns.
6. Remove the front exhaust tube.
Refer to Front Exhaust Tube Replacement.
7. Remove the engine under cover.
8. Remove the right (passenger side) front wheel.
9. Remove the fender protector side cover from the right side (passenger side) wheel housing.
^ Side cover is held on with 5 clips.
10. Remove the drive belt as follows:
CAUTION:
^ Do not loosen (do not turn counterclockwise) the auto-tensioner pulley bolt. If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including the pulley (which is not covered in this campaign).
^ Avoid placing a hand in a location where pinching may occur if the wrench accidentally comes off.
a. Use a 14 mm off-set box wrench on the auto-tensioner pulley bolt.
b. Pull / push on the wrench as if turning the bolt in a clockwise direction.
c. While holding / pulling the wrench, insert a rod (approximately 6 mm / 0.24 inch diameter and at least 25 mm / 1 inch long) through the tensioner retaining boss.
NOTE:
For illustration, a 6 mm Allen driver was used to hold the tensioner / retaining boss.
d. Carefully allow the tensioner to move to a relaxed position (carefully release your pulling force on the wrench).
e. Remove the drive belt.
11. Remove the alternator as follows (refer to Figure M7):
a. Disconnect B-terminal nut and remove B-terminal wire.
b. Remove alternator harness ground bolt.
C. Disconnect electrical harness from the alternator.
d. Remove 2 bolts holding the alternator to alternator bracket and engine.
e. Remove the alternator from the vehicle upward (from the top of the engine).
f. Remove 2 bolts holding the alternator bracket to the engine.
g. Remove the alternator bracket from the vehicle.
12. Remove the exhaust manifold as follows (refer to Figure M8).
a. Disconnect the Air Fuel (A/F) sensor harness and remove the A/F sensor from the exhaust manifold.
^ If the sensor is seized in the manifold, refer to NTB10-099 for sensor removal.
CAUTION:
Do not drop the A/F sensor.
b. Remove the lower exhaust manifold cover.
c. Remove the upper exhaust manifold cover.
d. Remove the exhaust manifold stay and discard.
^ Manifold stay is held on with a bolt to the engine and nut to the manifold.
^ The stay will not be reinstalled - discard the exhaust manifold stay.
e. Remove the exhaust manifold nuts in the order shown.
f. Remove the exhaust manifold from the vehicle.
13. Remove the exhaust manifold gasket.
14. Clean any exhaust manifold gasket residue form the engine head.
15. Install a new exhaust manifold gasket.
NOTE:
The exhaust manifold and gasket must be used as a matched set. Refer to the Parts Information for part number details.
16. Swap the 3 studs for the front tube connection from the old exhaust manifold to the new exhaust manifold.
17. Install the new exhaust manifold.
^ Use new nuts.
^ Torque the nuts in the order shown.
^ Torque nuts in two stages:
1st stage - 20.0 N~m (2.0 kg-m, 15 ft-lb)
2nd stage -41.7 N~m (4.3 kg-m, 31 ft-lb)
18. Reinstall all other parts in reverse order.
^ Refer to Figures M8 - page 17, M7 - page 16, and T3 - page 12 for torque specifications.
^ Use new bolts for Heat shield attachment. Use new nuts for front tube attachment.
19. Reconnect the negative battery cable.
20. Set the clock and the radio station presets.
21. If equipped; reset customer's settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed.)
22. Initialize auto-up power windows as follows:
a. Turn the ignition ON (keep the transmission in Park and the parking brake applied).
b. Close the door.
c. Operate the power window switch to fully open the window.
d. Pull UP and continue to pull UP on the power window switch to fully close the window.
e. Continue pulling the power window switch UP for 4 seconds after glass stops at fully closed position.
f. Check that auto-up function operates normally.