Exhaust Manifold: Service and Repair

Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Raise and support the vehicle. Refer to Vehicle Lifting.

Exhaust Manifold Removal with PUP Catalytic Converter





1. Remove the four bolts and separate the lower exhaust pipe from the exhaust manifold.
2. Remove the exhaust manifold stiffener bracket from the exhaust manifold.
3. Lower the vehicle.
4. Disconnect the oxygen sensor electric connector.





5. Remove the three bolts and the exhaust manifold heat shield (1) from the exhaust manifold.
6. If vehicle is equipped with A/C, remove the low side A/C line bracket and carefully reposition the A/C lines.
7. Remove the eight bolts and the one nut from the exhaust manifold.
8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket (1) from the cylinder head.

Exhaust Manifold Removal without PUP Catalytic Converter





1. Remove the two bolts and the front pipe/catalytic converter assembly (2) from the exhaust manifold (1).
2. Lower the vehicle.
3. Disconnect the oxygen sensor electric connector.





4. Remove the four bolts and the exhaust manifold heat shield (5) from the exhaust manifold.
5. If vehicle is equipped with A/C, remove the low side A/C line bracket and carefully reposition the A/C lines.
6. Remove the five bolts and the three nuts from the exhaust manifold.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket (1) from the cylinder head.

Exhaust Manifold Installation with PUP Catalytic Converter





1. Install the new exhaust manifold gasket (2) to the cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the exhaust manifold (3). Secure the exhaust manifold with the eight bolts and one nut.
Tighten the exhaust manifold bolts and nut to 32 Nm (24 ft. lbs.).
3. Install the exhaust manifold heat shield (1) to the exhaust manifold. Secure the exhaust manifold heat shield with the three bolts.
Tighten the heat shield bolts to 15 Nm (11 ft. lbs.).
4. Install the low side A/C line bracket. Secure the low side A/C line bracket with one bolt.
Tighten the low side A/C line bracket bolt to 15 Nm (11 ft. lbs.).
5. Raise and support the vehicle. Refer to Vehicle Lifting.





6. Install the exhaust manifold stiffener bracket. Secure the bracket with the two bolts.
Tighten the exhaust manifold stiffener bracket bolts to 50 Nm (37 ft. lbs.).
7. Install the front pipe assembly to the exhaust manifold with the new seal. Secure the assembly with the four bolts.
Tighten the exhaust manifold-to-front pipe assembly bolts to 50 Nm (37 ft. lbs.).
8. Lower the vehicle.
9. Connect the oxygen sensor electrical connector.
10. Connect the negative battery cable.
11. Check the exhaust system for exhaust gas leakage.

Exhaust Manifold Installation without PUP Catalytic Converter





1. Install the new exhaust manifold gasket (1) to the cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

2. install the exhaust manifold (2). Secure the exhaust manifold with the five bolts and the three nuts.
Tighten the exhaust manifold bolts and nuts to 23 Nm (17 ft. lbs.).
3. Install the exhaust manifold heat shield (6) to the exhaust manifold. Secure the exhaust manifold heat shield with the four bolts.
Tighten the heat shield bolts to 15 Nm (11 ft. lbs.).
4. Install the low side A/C line bracket. Secure the low side A/C line bracket with one bolt.
Tighten the low side A/C line bracket bolt to 15 Nm (11 ft. lbs.).
5. Raise and support the vehicle. Refer to Vehicle Lifting.





6. Install the front pipe/catalytic converter assembly (2) to the exhaust manifold with the new seal. Secure the assembly with the two bolts.
Tighten the exhaust manifold-to-front pipe/catalytic converter assembly bolts to 50 Nm (37 ft. lbs.).
7. Lower the vehicle.
8. Connect the oxygen sensor electrical connector.
9. Connect the negative battery cable.
10. Check the exhaust system for exhaust gas leakage.