Exhaust Manifold: Service and Repair

Fig. 4 Exhaust Manifold Replacement:

NON-TURBOCHARGED MODELS

1. Disconnect battery ground cable.
2. Remove air cleaner, then remove spark plug wires and retainers.
3. Remove oil dipstick tube and breather.
4. Disconnect oxygen sensor electrical connectors.
5. Remove exhaust pipe, then remove exhaust manifold attaching nuts.
6. Remove exhaust manifold and gasket.
7. Reverse procedure to install. Refer to Fig. 4, for manifold bolt tightening sequence. Tighten attaching nuts to specifications.

Fig. 5 Exhaust Manifold Bolt Tightening Sequence. Turbocharged Models:

TURBOCHARGED MODELS

1. Disconnect battery ground cable.
2. Remove spark plug wires.
3. Remove turbocharger as follows:
a. Raise and support vehicle.
b. Remove lower fan attaching screw.
c. Remove exhaust pipe to manifold attaching nuts, then remove exhaust pipe.
d. Remove rear A/C support bracket attaching bolt, then loosen remaining A/C support bracket bolts.
e. Remove turbo support bracket to engine attaching bolt.
f. Remove oil drain hose at turbo, then remove water return pipe.
g. Lower vehicle, then disconnect coolant recovery pipe and position to one side.
h. Remove oxygen sensor.
i. Remove oil and water feed pipes.
j. Remove air intake duct and vacuum hose at actuator.
k. Remove exhaust manifold attaching nuts, then remove exhaust manifold and turbocharger assembly.
4. Remove turbocharger to exhaust manifold attaching bolts, then remove exhaust manifold and gasket.
5. Reverse procedure to install. Refer to Fig. 5, for exhaust manifold attaching bolt sequence. Torque attaching nuts and bolts to specifications.