Exhaust Manifold Replacement - Right

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 throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
4. Remove the engine mount strut. Refer to Engine Mount Strut Replacement.
5. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
6. Disconnect the fuel lines from the fuel rail. Refer to Fuel Rail Assembly Replacement in Powertrain Management.
7. Disconnect the throttle control cable and the cruise control cable from the throttle linkage at the throttle body bracket. Refer to Accelerator Controls Cable Bracket Replacement in Powertrain Management and Cruise Control Cable Replacement in Cruise Control.
8. Disconnect the transaxle selector range cable.
9. Remove the transaxle shift cable brackets and bolts. Refer to Automatic Transmission Range Selector Cable Bracket Replacement in Transmission and Drivetrain.
10. Remove the transaxle shift cable from the shift module. Refer to Automatic Transmission Range Selector Cable Replacement (At PNP Switch) or Automatic Transmission Range Selector Cable Replacement (At Shift Control) or Automatic Transmission Range Selector Cable Replacement (New Cable Installation) in Transmission and Drivetrain.
11. Disconnect the vacuum booster hose from the engine.
12. Disconnect the wiring harness connections from the engine and the transaxle.
13. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
14. Remove the inlet radiator hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
15. Disconnect the transmission oil cooler lines from the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Transmission and Drivetrain.
16. Disconnect the surge tank inlet hose.
17. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
18. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
19. Remove the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Air Baffle) or Radiator Air Baffle Assemblies and Deflectors (Lower) or Radiator Air Baffle Assemblies and Deflectors (Side) in Cooling System.
20. Remove the battery cables from the retainers.
21. Remove the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet in Cooling System.
22. Remove the AC compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
23. Support the AC compressor.
24. Remove the wiring harness from the starter motor. Refer to Starter Motor Replacement in Starting and Charging.
25. Remove the three-way catalytic converter from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.
26. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Steering and Suspension.
27. Remove the inner fender engine splash shields. Refer to Splash Shield Replacement - Engine in Body and Frame.
28. Remove the wheel speed sensor wiring harnesses from the lower control arms.
29. Remove the tie rod ends from the steering knuckles. Refer to Tie Rod End Replacement - Outer in Steering and Suspension.
30. Remove the lower ball joints from the steering knuckles. Refer to Lower Ball Joint Replacement in Steering and Suspension.
31. Disconnect the drive axles. Support the drive axles. Refer to Wheel Drive Shafts Replacement (Left) or Wheel Drive Shafts Replacement (Right) in Transmission and Drivetrain.
32. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
33. Suitably secure the vehicle to the hoist.
34. Place the engine/frame support table under the vehicle.
35. Lower the vehicle to meet the engine/frame support table. Adjust the contact pads as necessary.
36. Remove the frame-to-body bolts. Refer to Frame Replacement in Body and Frame.
37. Raise the body of vehicle.
38. Remove the right (rear) exhaust manifold exhaust crossover pipe bolts from the left (front) exhaust manifold.
39. Disconnect the EGR valve pipe (1) from the exhaust crossover pipe.





40. Remove the right (rear) exhaust manifold retaining bolts.





41. Remove the right (rear) exhaust manifold and the gasket. Do not reuse the gasket.
42. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Clean and Inspect (Left) or Exhaust Manifold Clean and Inspect (Right).
43. Remove the oxygen sensor (1) and inspect the sensor for excessive deposits or damage. Replace the oxygen sensor if necessary. Refer to Heated Oxygen Sensor (HO2S) Replacement in Powertrain Management.





44. Remove the exhaust manifold stud(s) if damaged.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.





1. Install the exhaust manifold stud(s) if removed.
Tighten the exhaust manifold stud(s) to 6 Nm (53 inch lbs.).
2. Install the oxygen sensor. Refer to Heated Oxygen Sensor (H02S) Replacement in Powertrain Management.





3. Position a new right (rear) exhaust manifold gasket onto the right (rear) exhaust manifold.
4. Install the right (rear) exhaust manifold bolts.
5. Place the right (rear) exhaust manifold, gasket and bolts as an assembly in position on the cylinder head.





6. Install the right (rear) exhaust manifold retaining bolts.
Tighten the right (rear) exhaust manifold bolts to 25 Nm (18 ft. lbs.).
7. Install the right (rear) exhaust manifold exhaust crossover pipe bolts to the left (front) exhaust manifold.





8. Connect the EGR valve pipe nut (3) to the exhaust crossover pipe.
Tighten the EGR to exhaust crossover pipe nut to 60 Nm (44 ft. lbs.).
9. Lower the vehicle to the frame.
10. Install new frame-to-body bolts. Refer to Frame Replacement in Body and Frame.
11. Raise the vehicle.
12. Remove the engine/frame support table from under the vehicle.
13. Install the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
14. Install the drive axles. Refer to Wheel Drive Shafts Replacement (Left) or Wheel Drive Shafts Replacement (Right) in Transmission and Drivetrain.
15. Install the lower ball joints to the steering knuckles. Refer to Lower Ball Joint Replacement in Steering and Suspension.
16. Install the tie rod ends to the steering knuckles. Refer to Tie Rod End Replacement - Outer in Steering and Suspension.
17. Install the wheel speed sensor wiring harnesses to the lower control arms.
18. Install the inner fender engine splash shields. Refer to Splash Shield Replacement - Engine in Body and Frame.
19. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Steering and Suspension.
20. Install the three-way catalytic converter to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.
21. Install the starter motor wiring harness. Refer to Starter Motor Replacement in Starting and Charging.
22. Install the AC compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
23. Install the radiator outlet hose. Refer to Radiator Hose Replacement - Outlet in Cooling System.
24. Install the battery cables to the retainers.
25. Install the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Air Baffle) or Radiator Air Baffle Assemblies and Deflectors (Lower) or Radiator Air Baffle Assemblies and Deflectors (Side) in Cooling System.
26. Remove the safety straps.
27. Lower the vehicle.
28. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
29. Install the surge tank inlet hose.
30. Connect the transmission oil cooler lines to the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Transmission and Drivetrain.
31. Install the radiator inlet hose to the radiator. Refer to Radiator Hose Replacement - Inlet in Cooling System.
32. Connect the wiring harness connections at the engine and the transaxle.
33. Connect the vacuum booster hose to the engine.
34. Install the transaxle shift cable to the shift module. Refer to Automatic Transmission Range Selector Cable Replacement (At PNP Switch) or Automatic Transmission Range Selector Cable Replacement (At Shift Control) or Automatic Transmission Range Selector Cable Replacement (New Cable Installation) in Transmission and Drivetrain.
35. Install the transaxle shift cable bracket and bolts. Refer to Automatic Transmission Range Selector Cable Bracket Replacement in Transmission and Drivetrain.
36. Connect the transaxle selector range cable.
37. Connect the throttle cable and the cruise control cable to the throttle linkage on the throttle body bracket. Refer to Accelerator Controls Cable Bracket Replacement in Powertrain Management and Cruise Control Cable Replacement in Cruise Control.
38. Connect the fuel lines to the fuel rail. Refer to Fuel Rail Assembly Replacement in Powertrain Management.
39. Install the engine mount strut. Refer to Engine Mount Strut Replacement.
40. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
41. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
42. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
43. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
44. Check for leaks from the following areas:
^ Cooling system
- Engine
- Transmission
^ Exhaust system