Exhaust Manifold: Service and Repair

REMOVAL
1. Disconnect negative cable from battery.
2. Raise vehicle on hoist.






3. Remove bolt attaching the wire harness heat shield to the exhaust manifold support bracket (Federal and LEV), or to the exhaust manifold (ULEV).






4. Remove exhaust manifold support bracket (Federal and LEV).
5. Remove fasteners attaching exhaust system flex joint to exhaust manifold flange. Move exhaust system rearward to clear flange studs.






6. ULEV equipped-remove the support bracket from cylinder block to exhaust manifold.
7. Lower vehicle.
8. Disconnect CCV hose from rear of cylinder head cover.
9. Disconnect oxygen sensor connector and harness clip.






10. Remove heat shield attaching bolts.
11. Remove upper heat shield for access to manifold bolts.
12. Remove exhaust manifold bolts.
13. ULEV equipped-remove cylinder head cover. Cover cylinder head opening with a suitable covering.
14. Remove exhaust manifold from top of vehicle, between cylinder head and cowl.

INSTALLATION
1. Position exhaust manifold and gasket in place.






2. Install exhaust manifold bolts and tighten in sequence shown in figure to 23 Nm (200 inch lbs.).
3. ULEV equipped-position upper heat shield on exhaust manifold. Install bolts and tighten to 23 Nm (200 inch lbs.).
4. Position lower and upper heat shield on exhaust manifold. Install heat shield bolts and tighten to 11 Nm (95 inch lbs.).
5. Connect oxygen sensor electrical connector and harness clip.
6. ULEV equipped-install cylinder head cover.
7. Connect CCV hose on cylinder head cover port.
8. Raise vehicle.
9. Install new flex joint to manifold flange gasket.
10. Attach exhaust system to manifold flange and tighten fasteners to 28 Nm (250 inch lbs.).
11. Install exhaust manifold support bracket (Federal and LEV). Tighten M10 bolt to 54 Nm (40 ft. lbs.), M12 bolt to 95 Nm (70 ft. lbs.), and nut to 28 Nm (250 inch lbs.).
12. ULEV equipped-install support bracket to cylinder block and exhaust manifold. Snug all bolts first then tighten to 54 Nm (40 ft. lbs.).
13. Install bolt attaching wire harness heat shield to support bracket (Federal and LEV), or exhaust manifold (ULEV).