Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement

Removal Procedure





1. Disconnect the battery negative cable.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Remove the drive belt.
4. Remove the exhaust pipe from the exhaust manifold.
5. Lower the vehicle.
6. Remove the upper fan shroud.

Important: Do not evacuate the air conditioning system.

7. Remove the air conditioning compressor, if equipped, and set it aside.
8. Remove the power steering pump and set it aside, using the following procedure:
8.1. Two nuts from the cylinder head studs
8.2. One bolt from the rear bracket
8.3. Three bolts from the front of the power steering pump The bolts are accessible through the holes in the power steering pump pulley.
9. Remove the oil level indicator tube.





10. Disconnect the oxygen sensor electrical connection.





11. Remove the oxygen sensor from the exhaust manifold to prevent damage to the sensor.





12. Remove the air injection nuts (1, 2).
13. Remove the air injection pipe from the exhaust manifold.





14. Remove the exhaust manifold nuts.
15. Remove the exhaust manifold.
16. Remove the exhaust manifold gasket.





17. Remove the heat shield, if replacing the exhaust manifold.
18. Clean all sealing surfaces.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.





1. Install the heat shield and bolts to the exhaust manifold, if removed.
^ Tighten the heat shield bolts to 12 Nm (106 inch lbs.).





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





4. Install the air injection pipe with gasket.
^ Tighten the air injection pipe nut (1) to 13 Nm (115 inch lbs.).
^ Tighten the air injection pipe nut (2) to 10 Nm (89 inch lbs.).
5. Install the oxygen sensor, if removed.
6. Install the oil level indicator tube.





7. Install the power steering pump.
7.1. Loosely install the power steering pump to accessory mounting bracket 3 bolts.
7.2. Loosely install the 2 nuts holding the power steering pump bracket to the cylinder head studs.
7.3. Loosely install the power steering pump lower bracket bolt.
8. Tighten the fasteners in the following sequence:
8.1. Tighten the accessory mounting bracket 3 bolts to 30 Nm (22 ft. lbs.).
8.2. Tighten the cylinder head stud 2 nuts to 50 Nm (37 ft. lbs.).
8.3. Tighten the lower bracket bolt to 50 Nm (37 ft. lbs.).
9. Install the air conditioning compressor, if equipped.
10. Raise the vehicle. Refer to Vehicle Lifting.
11. Install the exhaust pipe to the exhaust manifold.
12. Install the drive belt.
13. Lower the vehicle.
14. Install the upper fan shroud.
15. Connect the battery negative cable.