Exhaust Manifold Replacement - Left

Removal Procedure





1. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement.
2. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement - Lower.
3. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.





4. Disconnect the Exhaust Gas Recirculation (EGR) valve inlet pipe from the exhaust manifold.





5. Remove the radiator inlet hose support bracket and nut.





6. Remove the nuts holding the secondary Air Injection (AIR) pipe to the exhaust manifold, if equipped.
7. Remove the AIR pipe and gasket from the exhaust manifold.
8. Raise the vehicle. Refer to Vehicle Lifting.
9. Disconnect the exhaust pipe from the exhaust manifold.
Refer to Catalytic Converter Replacement.
10. Lower the vehicle to the proper height.
11. Remove the front tire to gain access to the rear exhaust manifold bolts. Refer to Tire and Wheel Removal and Installation.





12. Remove the fender wheelhouse extension.
13. Working through the wheel house opening disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement.





14. Remove the exhaust manifold bolts and the stud.
15. Lower the vehicle.
16. From under the hood remove the exhaust manifold and the spark plug wire shields from the engine.
17. Clean all gasket surfaces. Refer to Exhaust Manifold Clean and Inspect.

Installation Procedure





Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and bolts in place.

1. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold. The stud installs in the front hole.
2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. From under the hood position the exhaust manifold by the engine.
4. Raise the vehicle to the proper height.
5. Working the wheelhouse opening install the exhaust manifold. Refer to Exhaust Manifold Installation (Left).
6. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire Hamess Replacement (4.3L) or Spark Plug Wire Harness Replacement (2.2L).





7. Install the fender wheelhouse extension.
8. Install the front tire to. Refer to Tire and Wheel Removal and Installation.
9. Raise the vehicle.
10. Connect the exhaust pipe to the exhaust manifold.
Refer to Catalytic Converter Replacement.
11. Lower the vehicle.





Notice: Refer to Fastener Notice in Service Precautions.

12. Connect the EGR valve inlet pipe to the exhaust manifold.

^ Tighten the EGR valve inlet pipe nut to 30 Nm (22 ft. lbs.).





13. Connect the ECT sensor electrical connector.





14. Install the AIR pipe and a NEW gasket to the exhaust manifold.
15. Install the AIR pipe nuts.

^ Tighten the AIR pipe nuts to 25 Nm (18 ft. lbs.).





16. Install the radiator inlet hose support bracket and nut.

^ Tighten the radiator inlet hose support bracket nut to 36 Nm (27 ft. lbs.).

17. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement -Lower.
18. Install the air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement.