Exhaust Manifold: Service and Repair

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the oxygen sensor lead.
4. Remove the drive belt. Refer to Drive Belt Replacement.
5. Remove the generator rear brace.
6. Remove the generator. Refer to Generator Replacement.





7. Remove the radiator inlet pipe.
8. Raise and support the vehicle. Refer to Vehicle Lifting.
9. Remove the exhaust pipe to the exhaust manifold.
10. Lower the vehicle.
11. Remove the oil fill tube. Refer to Oil Level Indicator and Tube Replacement.
12. Remove the heater outlet hose assembly nut from the exhaust manifold.





13. Remove the exhaust manifold nuts.
14. Remove the exhaust manifold and the gasket.
15. Clean the mating surfaces at the cylinder head and the exhaust manifold.
16. Inspect the manifold for cracks, broken flanges and gasket surface damage.
17. Check the alignment of the exhaust manifold mating surfaces. Use a straight edge and a feeler gauge. If the flanges or the mating surfaces do not align, the manifold is warped and should be replaced.

Installation Procedure





1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the exhaust manifold nuts.
^ Tighten the nuts to 13 Nm (115 inch lbs.).





4. Install the heater outlet hose assembly nut.
^ Tighten the nut to 25 Nm (18 ft. lbs.).
5. Install the oil fill tube. Refer to Oil Level Indicator and Tube Replacement.
6. Raise the vehicle.
7. Install the exhaust pipe to the manifold. Refer to Intermediate Pipe Replacement.
8. Lower the vehicle.
9. Install the radiator inlet pipe.





10. Install the generator. Refer to Generator Replacement.
11. Install the generator rear brace.
12. Install the drive belt. Refer to Drive Belt Replacement.
13. Install the oxygen sensor lead.
14. Connect the negative battery cable.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
15. Refill the cooling system, Refer to Draining and Filling Cooling System in Cooling System.