Exhaust Manifold: Service and Repair

WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down.





REMOVAL
1. Disconnect negative cable at battery.
2. Remove air intake pipe and remove its bracket.
3. Disconnect heated oxygen sensor coupler.
4. Remove upper cover of exhaust manifold.





5. Remove or disconnect exhaust pipe from exhaust manifold.





6. Remove exhaust manifold stiffener.
7. Remove exhaust manifold and its gasket from cylinder head.

INSPECTION






- Refer to removal and installation procedures of exhaust manifold. Refer to removal and installation procedures of HO2S-2.
- For replacement of exhaust No.1 pipe, exhaust No.2 pipe, muffler or any part used to mount or connect them, be sure to hoist vehicle and observe WARNING given at the left of this page.

CAUTION: As exhaust No.2 pipe has three way catalytic converter in it, it should not be exposed to any impulse. Be careful not to drop it or hit it against something.

- When exhaust manifold is removed, check gaskets and seal for deterioration or damage. Replace them as necessary.
- Tighten bolts and nuts to specified torques when reassembling. Refer to figure for location of bolts and nuts.

Tightening Torque
(a): 50 Nm (36.5 ft. lbs.)
(b): 60 Nm (43.5 ft. lbs.)

- There are three types of muffler mounting. Refer to figure for their correct use.

INSTALLATION





1. Install new gasket to cylinder head.





2. Install exhaust manifold and stiffener. Tighten bolts and nuts to specified torque.

Tightening Torque (a): 23 Nm (17.0 ft. lbs.)





3. Install pipe gasket and install exhaust pipe to exhaust manifold. Before installing pipe gasket, check it for deterioration or damage, and replace as necessary. Tighten pipe fasteners to specified torque.

Tightening Torque (a): 45 Nm (32.5 ft. lbs.)





4. Install upper cover to exhaust manifold.
5. Connect heated oxygen sensor coupler and clamp its wire securely.
6. Install air intake pipe and its bracket.
7. Connect negative cable at battery.
8. Check exhaust system for exhaust gas leakage.