Exhaust Manifold Replacement - Left

Removal Procedure





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
3. Remove the engine mount strut. Refer to Engine Mount Strut Replacement.
4. Remove the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement (Upper Radiator Support) or Engine Mount Strut Bracket Replacement (Engine).
5. Remove the engine cooling fans. Refer to Cooling Fan Replacement - Electric in Cooling System.
6. Drain the engine coolant from the engine. Refer to Draining and Filling Cooling System in Cooling System.
7. Remove the radiator inlet hose. Refer to Radiator Hose Replacement - Inlet in Cooling System.
8. Remove the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet in Cooling System.
9. Remove the transaxle cooler lines from the radiator.
10. Remove the radiator. Refer to Radiator Replacement in Cooling System.
11. Remove the generator. Refer to Generator Replacement in Starting and Charging.
12. Remove the exhaust manifold heat shield retaining bolts.
13. Remove the exhaust manifold heat shield.
14. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.





15. Disconnect the vacuum tube (1) from the A.I.R. control valve.
16. Disconnect the feed pipe nut (3) from the exhaust manifold.
17. Remove the A.I.R. control valve retaining bolt.
18. Remove the A.I.R. control valve from the engine mount strut bracket.





19. Loosen the exhaust manifold bolts.





20. Remove the left exhaust manifold to crossover pipe flange retaining studs (3) and the flange gasket (1).
21. Remove the exhaust manifold bolts (4).
22. Remove the exhaust manifold (5) and the gasket (6). DO NOT reuse the gasket.
23. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Clean and Inspect (Left) or Exhaust Manifold Clean and Inspect (Right).

Installation Procedure





1. Install a new manifold to crossover flange gasket onto the manifold flange.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the exhaust manifold to crossover pipe flange retaining studs.
Tighten the exhaust manifold to crossover flange studs to 25 Nm (18 ft. lbs.).
3. Position a new exhaust manifold gasket onto the manifold.
4. Install the exhaust manifold bolts.





5. Tighten the exhaust manifold bolts.
Tighten the exhaust manifold bolts to 25 Nm (18 ft. lbs.).





6. Install the A.I.R. control valve to the engine mount strut bracket.
7. Connect the feed pipe nut (3) to the exhaust manifold.
8. Install the A.I.R. control valve retaining bolt (2).
9. Connect the vacuum tube (1) to the A.I.R. control valve.
10. Install the control valve-to-engine mount strut bracket bolt.
Tighten the control valve retaining bolt to 9 Nm (80 inch lbs.).
11. Install the feed pipe nut (3).
Tighten the feed pipe nut to 60 Nm (44 ft. lbs.).
12. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.





13. Place the exhaust manifold heat shield in position.
14. Install the heat shield retaining bolts.
Tighten the heat shield retaining bolts to 9 Nm (80 inch lbs.).
15. Install the generator. Refer to Generator Replacement in Starting and Charging.
16. Install the radiator. Refer to Radiator Replacement in Cooling System.
17. Connect the transaxle cooler lines to the radiator.
18. Install the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet in Cooling System.
19. Install the radiator inlet hose. Refer to Throttle Body Heater Hose Replacement - Inlet in Cooling System.
20. Fill the engine cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
21. Install the radiator cooling fans. Refer to Cooling Fan Replacement - Electric in Cooling System.
22. Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement (Upper Radiator Support) or Engine Mount Strut Bracket Replacement (Engine).
23. Install the engine mount strut. Refer to Engine Mount Strut Replacement.
24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
25. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.