Exhaust Manifold: Service and Repair
RIGHT EXHAUST MANIFOLDREMOVAL
1. Disconnect negative cable from remote jumper terminal.
2. Remove air intake plenum and air filter housing.
3. Remove bolt attaching battery cable housing tube to transmission housing.
4. Remove bolts attaching EGR tube from exhaust manifold and EGR valve. Discard gaskets.
5. Disconnect electrical connector and remove exhaust manifold mounted oxygen sensor.
6. Loosen and remove the manifold to catalytic converter V-Band clamp.
NOTE: Do not reuse V-Band clamp.
7. Remove heat shield attaching screws and remove heat shields.
8. Remove exhaust manifold attaching bolts and remove manifold.
INSTALLATION
1. Install exhaust manifold and gasket. Tighten bolts working from center outwards to 23 Nm (200 inch lbs.).
2. Install heat shields. Tighten attaching screws to 12 Nm (105 inch lbs.).
3. Install a new V-Band clamp and tighten 10 Nm (100 inch lbs.).
4. Install oxygen sensor and connect electrical connector.
5. Install EGR tube using new gaskets. Tighten screws to 11 Nm (95 inch lbs.).
6. Install bolt attaching battery cable housing tube to transmission housing. Tighten bolt to 101 Nm (75 ft. lbs.).
7. Install air intake plenum and air filter housing.
8. Connect negative cable.
LEFT EXHAUST MANIFOLD
REMOVAL
1. Disconnect negative cable from remote jumper terminal.
2. Raise vehicle on hoist.
3. Remove exhaust system.
4. Remove left catalytic converter.
NOTE: Do not reuse V-Band clamp.
5. Remove bolt attaching transmission dipstick tube and rotate housing away from engine.
6. Lower vehicle.
7. Remove screws attaching the two electrical connectors and harness to support bracket.
8. Remove engine wiring harness support bracket from cylinder head.
9. Disconnect exhaust manifold mounted oxygen sensor connector and remove sensor from manifold.
10. Remove engine oil dipstick tube.
11. Remove heat shield attaching screws and remove heat shields.
12. Remove exhaust manifold attaching bolts and remove manifold.
INSTALLATION
1. Install exhaust manifold and gasket. Tighten bolts starting at the center working outward to 23 Nm (200 inch lbs.).
2. Install heat shields. Tighten screws to 12 Nm (105 inch lbs.).
3. Install oxygen sensor and connect electrical connector.
4. Raise vehicle on hoist.
5. Install bolt attaching transmission dipstick tube.
6. Replace the O-ring on engine oil dipstick tube and install tube.
7. Install catalytic converter.
8. Install a new V-Band clamp and tighten to 10 Nm (100 inch lbs.).
9. Install engine wiring harness support bracket to cylinder head and attach connectors to bracket.
10. Install exhaust system.
11. Connect negative cable.