Exhaust Manifold: Service and Repair

REMOVAL PROCEDURE





1. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Remove the top half of the air cleaner assembly. Remove the throttle body duct.
3. Remove the exhaust crossover heat shield.





4. Remove the exhaust crossover pipe at the exhaust manifold.
5. Remove the heated oxygen sensor.





6. Remove the EGR pipe at the exhaust manifold.
7. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting.
8. Remove the transmission oil level indicator and fill tube assembly. Refer to Filler Tube Replacement in Automatic Transaxle - 4T60-E.
9. Remove the exhaust pipe from the exhaust manifold.
10. Remove the exhaust pipe from the converter flange.
11. Support the converter aside.
12. Remove the converter heat shield from the vehicle body.





13. Remove the exhaust manifold heat shield: bolts.
14. Remove the exhaust manifold heat shield.





15. Remove the exhaust manifold nuts/studs.
16. Remove the exhaust manifold from the bottom of the vehicle.
17. Clean the mating surfaces at the cylinder head and at the exhaust manifold.

INSTALLATION PROCEDURE





1. Install the exhaust manifold gasket.
2. Install the exhaust manifold. Loosely, install, the heat shield at this time.
3. Install the exhaust manifold nuts/studs.
^ Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield-bolts.
^ Tighten the exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.).

6. Install the converter heat shield to the body.
7. Install the exhaust pipe to the converter flange.
8. Install the exhaust pipe to the exhaust manifold.
9. Install the transmission oil level indicator and fill tube assembly. Refer to Filler Tube Replacement in Automatic Transaxle - 4T60-E.
10. Lower the vehicle.
11. Install the heated oxygen sensor.
^ Tighten the oxygen sensor to 42 Nm (31 ft. lbs.).





12. Install the exhaust crossover pipe to the exhaust manifolds.
^ Tighten the exhaust nuts/studs to 25 Nm (18 ft. lbs.)





13. Install the exhaust crossover heat shield.
^ Tighten the exhaust crossover heat shield bolts to 10 Nm (89 inch lbs.).





14. Install the EGR pipe to the exhaust manifold.
^ Tighten the EGR pipe bolt to 25 Nm (18 ft. lbs.).

15. Install the top half of the air cleaner assembly. Install the throttle body duct.
16. Connect the negative battery cable..
17. Check for exhaust leaks.