Exhaust Manifold: Service and Repair
REMOVALRIGHT EXHAUST MANIFOLD
1. Disconnect negative cable to battery.
2. Remove right hood side panel.
3. Raise vehicle on hoist.
4. Loosen and remove air conditioning compressor drive belt.
5. Disconnect catalytic converter to exhaust manifold connection by loosening V-Band clamp.
NOTE: Do not reuse V-Band Clamp.
6. Lower vehicle.
7. Remove right headlamp module.
8. Remove air conditioning compressor from mounting bracket and set aside.
9. Remove engine oil dipstick and tube.
10. Remove compressor mounting bracket from engine.
11. Raise vehicle on hoist.
12. Disconnect exhaust manifold mounted oxygen sensor electrical connector and remove oxygen sensor from manifold.
13. Remove screws attaching upper and lower heat shields to manifold.
14. Remove bolts attaching manifold to cylinder head and remove manifold.
NOTE: The exhaust manifold is removed between the frame rail and catalytic converter from below vehicle.
LEFT EXHAUST MANIFOLD
1. Disconnect negative cable to battery.
2. Remove left hood side panel.
3. Remove Power Distribution Center (PDC) attaching screws and set PDC aside.
4. Lift power steering reservoir from mounting bracket and set aside.
5. Disconnect catalytic converter to exhaust manifold connection by loosening V-Band clamp.
NOTE: Do not reuse V-Band Clamp.
6. Disconnect exhaust manifold mounted oxygen sensor electrical connector and remove oxygen sensor from manifold.
7. Remove screws attaching upper and lower heat shields to manifold.
8. Remove bolts attaching manifold to cylinder head and remove manifold.
INSPECTION
Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface with a straightedge and thickness gauge.
INSTALLATION
RIGHT EXHAUST MANIFOLD
1. Position a new V-Band clamp onto manifold between the outlet flange and oxygen sensor boss.
2. Install manifold to cylinder head. Tighten manifold starting at center bolts and working outwards to 23 Nm (200 inch lbs.).
3. Install upper and lower heat shields to manifold and tighten attaching screws to 12 Nm (105 inch lbs.).
4. Install oxygen sensor to manifold and tighten to 28 Nm (20 ft. lbs.). Connect oxygen sensor electrical connector.
5. Attach catalytic converter to manifold using a new V-Band clamp and tighten to 11 Nm (100 inch lbs.).
6. Lower vehicle and install air conditioning compressor mounting bracket to engine.
7. Inspect dipstick tube O-ring. Replace as necessary.
8. Install engine oil dipstick and tube.
9. Install compressor to mounting bracket. Tighten compressor bolts to 28 Nm (250 inch lbs.).
10. Install air conditioning compressor drive belt.
11. Install right headlamp module.
12. Install right hood side panel.
13. Connect negative cable to battery.
LEFT EXHAUST MANIFOLD
1. Position a new V-Band clamp onto exhaust manifold between the outlet flange and oxygen sensor boss.
2. Install manifold to cylinder head. Tighten manifold starting at center bolts and working outward to 23 Nm (200 inch lbs.)
3. Install upper and lower heat shields to manifold. Tighten attaching screws to 12 Nm (105 inch lbs.).
4. Install oxygen sensor to manifold and tighten to 28 Nm (20 ft. lbs.). Connect oxygen sensor electrical connector.
5. Attach catalytic converter to manifold using a new V-Band clamp and tighten to 11 Nm (100 inch lbs.).
6. Install power steering reservoir into support bracket.
7. Install Power Distribution Center (PDC).
8. Install left hood side panel.
9. Connect negative cable to battery.