Exhaust Manifold: Service and Repair

REMOVAL

1. Disconnect battery ground cable.
2. Remove air cleaner bonnet/inlet hose from throttle body and air cleaner.
3. Loosen EGR tube nut from intake manifold and bolts from the exhaust manifold.
4. Disconnect exhaust down pipe from exhaust manifold.
5. Remove power steering pump and brackets from water pump and intake manifold, then position aside.
6. Remove fuel tank filler to relive pressure, then reinstall cap.
7. With finger pressure, disconnect cruise control connector from throttle body.
8. Disconnect electrical connectors for throttle position sensor, idle speed control motor, coolant temperature sensor from thermostat, coolant temperature sensor from intake manifold, fuel injector, air temperature sensor and oxygen sensor, then position harness aside.
9. Disconnect crankcase ventilation vacuum hose and MAP sensor vacuum hose connector from throttle body.
10. Disconnect vacuum hose from vacuum port on intake manifold.
11. Disconnect vacuum hose from EGR transducer, also vacuum hoses from EGR solenoid on drivers side of engine compartment.
12. Disconnect CCV hose from valve cover.
13. Remove molded vacuum harness.
14. Disconnect vacuum brake booster hose from intake manifold.
15. Loosen EGR tube nut from intake manifold and remove bolts securing EGR tube to exhaust manifold.
16. Install Mot. 453.01 clamps to heater hoses at front and rear of intake manifold.
17. Remove heater hose clamps and disconnect hoses from intake manifold.
18. Remove intake manifold, exhaust manifold and EGR tube as an assembly.
19. Remove EGR tube bolts from exhaust manifold and separate manifolds.
20. Drain coolant from manifold.

Fig. 10 Intake & Exhaust Manifold Bolt Sequence:

Fig. 11 Exhaust Manifold Alignment Spacers:

INSTALLATION

1. Drain coolant from manifold. Clean intake and exhaust manifold surface.
2. Clean EGR tube to exhaust manifolds surface.
3. Install new intake manifold gasket over locating dowels.
4. Install new exhaust manifold alignment spacers (L).
5. Connect EGR tube loosely to exhaust manifold with new gasket.
6. Position manifold in place and finger tighten mounting bolts.
7. Torque bolts in sequence as follows:
a. Bolts 1, 6, 7 and 8, to 30 ft. lbs.
b. Bolts 2, 3, 4 and 5 to 23 ft. lbs.
c. Bolts 9 and 10 to 14 ft. lbs.
8. Refer to Removal procedure to complete installation. Torque exhaust down pipe bolts to 25 ft. lbs.
9. Fill cooling system to proper level.