Exhaust Manifold: Service and Repair

Removal Procedure





1. Disconnect the battery negative cable. Refer to Battery Replacement.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Remove the drive belt. Refer to Drive Belt Replacement.
4. Remove the exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement.
5. Lower the vehicle.
6. Remove the upper fan shroud. Refer to Fan Shroud Replacement in Cooling System.

Important: Do not evacuate the air conditioning system.

7. Remove the air conditioning compressor, if equipped, and set it aside. Refer to Compressor Replacement in Heating and Air Conditioning.
8. Remove the power steering pump and set it aside, using the following procedure:
8.1. Two nuts from the cylinder head studs
8.2. One bolt from the rear bracket
8.3. Three bolts from the front of the power steering pump
The bolts are accessible through the holes in the power steering pump pulley.
9. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement.





10. Disconnect the oxygen sensor electrical connection (LN2 engine only).
11. Remove the oxygen sensor if replacing the exhaust manifold. Refer to 02S Replacement.
12. Remove the exhaust manifold and the gasket.





13. Remove the heat shield, if replacing the exhaust manifold.
14. Clean all sealing surfaces. Refer to Exhaust Manifold Clean and Inspect.

Installation Procedure





Notice: Refer to Fastener Notice in Service Precautions.

1. Install the heat shield and bolts to the exhaust manifold, if removed.

^ Tighten the heat shield bolts to 12 Nm (106 inch lbs.).

2. Install the exhaust manifold. Refer to Exhaust Manifold Installation.
3. Install the oxygen sensor, if removed. Refer to 02S Replacement.
4. Connect the oxygen sensor electrical connector (LN2 engine only).
5. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement.





6. Install the power steering pump.
6.1. Loosely install the power steering pump to accessory mounting bracket three bolts.
6.2. Loosely install the two nuts holding the power steering pump bracket to the cylinder head studs.
6.3. Loosely install the power steering pump lower bracket bolt.
7. Tighten the fasteners in the following sequence:

7.1. Tighten the accessory mounting bracket three bolts to 30 Nm (22 ft. lbs.).
7.2. Tighten the cylinder head stud two nuts to 50 Nm (37 ft. lbs.).
7.3. Tighten the lower bracket bolt to 50 Nm (37 ft. lbs.).

8. Install the air conditioning compressor, if equipped. Refer to Compressor Replacement in Heating and Air Conditioning.
9. Raise the vehicle.
10. Install the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement.
11. Install the drive belt. Refer to Drive Belt Replacement.
12. Lower the vehicle.
13. Install the upper fan shroud. Refer to Fan Shroud Replacement in Cooling System.
14. Connect the battery negative cable. Refer to Battery Replacement.