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 Cooling System Service and Repair.
3. Remove the oxygen sensor lead.





4. Remove the drive belt.
5. Remove the generator rear brace.
6. Remove the generator.
7. Remove the radiator inlet pipe.
8. Raise and support the vehicle. Refer to Vehicle Lift points
9. Remove the exhaust pipe to the exhaust manifold.
10. Lower the vehicle.
11. Remove the oil fill tube.
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.
6. Raise the vehicle. Refer to Vehicle Lift Points.
7. Install the exhaust pipe to the manifold.
8. Lower the vehicle.
9. Install the radiator inlet pipe.





10. Install the generator.
11. Install the generator rear brace.
12. Install the drive belt.
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 Cooling System Service and Repair.