Exhaust Manifold: Service and Repair

REMOVAL
1. Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at articulated joint.

Fig. 16 EGR Tube, Heated Oxygen Sensor And Alternator/Power Steering Strut:

2. Separate EGR tube from rear manifold and disconnect Heated Oxygen Sensor lead wire.
3. Remove Alternator/Power Steering Support Strut.
4. Remove bolts attaching cross-over pipe to manifold.
5. Remove bolts attaching rear manifold to cylinder head and remove manifold.

Fig. 17 Heat Shield:

6. Lower vehicle and remove screws attaching front heat shield to front manifold.

Fig. 18 Crossover Pipe:

7. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head. Remove assemblies.

Fig. 19 Check Exhaust Manifold Mounting Surface:

INSPECTION
Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge.

INSTALLATION
1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 in.lbs.).
2. Attach exhaust pipe to exhaust manifold and tighten shoulder bolt to 28 Nm (250 in.lbs.).
3. Attach crossover pipe to exhaust manifold and tighten bolt to 33 Nm (25 ft.lbs.) and connect oxygen sensor lead.
4. Reinstall EGR Tube and Alternator/Power Steering Strut.
5. Install front exhaust manifold and attach exhaust crossover.
6. Install front manifold heat shield and tighten attaching screws to 23 Nm (200 in.lbs.).