Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution) .
1. Open the hood.
2. Disconnect the battery.

* Detach the negative connection from the ground terminal.
* Loosen the nut.

3. Remove the mixture regulator oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement (Service and Repair) .
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
5. Remove the resonator. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair) .
6. Remove the oil dipstick guide tube. Refer to Oil Level Indicator and Tube Replacement (Service and Repair) .
7. Raise the vehicle by its full height.




8. Release the wiring harness plug, oxygen sensor of the catalytic converter control (1).

* Disconnect the wiring harness connector (3).
* Disconnect the wiring harness (2) from the bracket





9. Remove the front exhaust pipe (2) from the catalytic converter (1).
Remove the 3 nuts (3).




10. Remove the heat shield from the catalytic converter.
Remove the 2 bolts.
11. Remove the exhaust system.
Remove the 6 damper rings.




12. Remove the catalytic converter from the catalytic converter bracket (1).
Remove the 2 bolts (3, 4).
13. Remove the bracket for the catalytic converter (1) from the cylinder block.
Remove the 2 bolts (2, 5).
14. If equipped with air conditioning, remove the drive belt. Refer to Drive Belt Replacement (Service and Repair) .




15. If equipped with air conditioning, remove the compressor. Refer to Air Conditioning Compressor Replacement (Service and Repair) .

* Remove the 3 bolts (1).
* Set aside.

16. Lower the vehicle by its full height.




17. Remove the 2 engine transport shackles (1).
Remove the 2 bolts (2).




18. Remove the exhaust manifold heat shield (3).

* Remove the wiring harness bracket (2).
* Remove the bolt (1).





19. Remove the exhaust manifold.
Remove the 9 nuts (1).



Installation Procedure

1. Clean the sealing surface.

Notice: Refer to Fastener Notice (Fastener Notice) .

2. Install the exhaust manifold.
Use new gasket and nuts.

Tighten the 9 nuts to 20 N.m (15 lb ft).

3. Replace the heat shield.
Install the wiring harness bracket of the oxygen sensor mixture regulator.

Tighten the bolt to 15 N.m (11 lb ft).

4. Raise the vehicle by its full height.
5. If equipped with air conditioning, install the compressor. Refer to Air Conditioning Compressor Replacement (Service and Repair) .

Tighten the 3 bolts to 22 N.m (16 lb ft).

6. In vehicles with air conditioning, install the drive belt. Refer to Drive Belt Replacement (Service and Repair) .
7. Install the catalytic converter bracket.
Install to the cylinder block.

Tighten the 2 bolts to 20 N.m (15 lb ft).

8. Install the catalytic converter to the bracket.

Tighten the 2 bolts to 20 N.m (15 lb ft).

9. Install the heat shield to the catalytic converter.

Tighten the 2 bolts to 8 N.m (70 lb in).

10. Install the exhaust system.
Install the 6 damper rings.
11. Install the front exhaust pipe to the catalytic converter.
Use a new gasket.

Tighten the 3 new nuts to 20 N.m (15 lb ft).

12. Install the catalytic converter control oxygen sensor wiring harness.

* Connect the wiring harness plug.
* Install the wiring harness into the bracket.

13. Install the oil dipstick guide tube. Refer to Oil Level Indicator and Tube Replacement (Service and Repair) .
14. Clean the 2 threads.
15. Install the 2 engine transport shackles.

Tighten the 2 bolts to 25 N.m (18 lb ft).

16. Install the bracket, wiring harness for the mixture regulator oxygen sensor to the cylinder head together with the exhaust manifold heat shield.

Tighten the bolt to 25 N.m (18 lb ft).

17. Install the mixture regulator oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement (Service and Repair) .
18. Install the resonator. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair) .
19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
20. Connect the battery.
Install the negative connection to the ground terminal.

Tighten the nut to 5 N.m (44 lb in).

21. Inspect and correct the engine oil level.
22. For programming procedures, refer to Control Module References (Programming and Relearning) .
23. Close the hood.