Exhaust Manifold: Service and Repair
Removal and InstallationWARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system has cooled off.
Removal
1. Disconnect negative (-) cable at battery.
2. Remove air cleaner upper case and intake air hose if right side exhaust manifold is removed.
3. Detach couplers from their bracket and disconnect oxygen sensor lead wires at couplers.
4. Disconnect EGR pipe from right (No. 2) bank exhaust manifold if right side exhaust manifold is removed.
5. Remove oil level gauge guide (3) if left side exhaust manifold is removed.
6. Detach P/S pump assembly as the following, if left side exhaust manifold is removed.
a. Loosen P/S pump drive belt by loosening tensioner bolt.
b. Remove P/S pump mounting bolts.
c. Detach P/S pump assembly with its hoses from cylinder block.
7. Remove exhaust manifold covers (2) from exhaust manifolds (1).
8. Hoist vehicle.
9. For 4WD vehicle, before disconnecting front propeller shaft, put match mark (1) on joint flange and propeller shaft to facilitate their installation as shown in the figure.
10. For 4WD vehicle, disconnect propeller shaft from front differential.
11. Remove exhaust No.1 pipe (1).
12. Remove exhaust manifold stiffeners (1).
13. Remove stabilizer bar mounting bolt and pull down stabilizer bar if right side exhaust manifold is removed.
14. Remove exhaust manifolds and their gaskets from cylinder heads.
Installation
1. Install new manifold gaskets to cylinder heads and No. 1 pipe gasket to exhaust No. 1 pipe.
2. Install exhaust manifolds.
^ Always install new bolts with pre-coated adhesive to the locations with * mark.
^ Tighten both manifold nuts and bolts to specified torque.
Tightening torque
Exhaust manifold bolt and nut (a): 30 Nm (3.0 kgf-m, 21.5 ft. lbs.)
3. Install stabilizer bar if it was removed.
4. Install exhaust manifold stiffeners.
5. Install exhaust No.1 (1) pipe.
Tighten exhaust No.1 pipe bolts and nuts to specified torque.
Tightening torque
Exhaust No.1 pipe bolt and nut (b): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
6. Reverse removal procedure to install front propeller shaft if removed.
When installing propeller shaft, align match mark (1).
Use the following specification to torque universal joint flange.
Tightening torque
Universal joint flange bolt (c): 55 Nm (5.5 kgf-m, 40.0 ft. lbs.)
7. Connect EGR pipe to left (No. 1) bank exhaust manifold (1).
8. Install exhaust manifold covers (2).
9. Install oil level gauge guide (3) using new O-ring.
10. Install P/S pump assembly (4) if it was removed.
11. Adjust P/S pump drive belt tension.
12. Connect oxygen sensor lead wire couplers. Be sure to clamp its lead wires.
13. Connect negative (-) cable to battery.
Upon completion of installation, start engine and check that no exhaust gas leakage exists.