Exhaust Manifold - Standard

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 (NLEV) , or to the exhaust manifold (ULEV).





4. Remove exhaust manifold support bracket (NLEV).
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 make-up air hose from rear of cylinder head cover.
9. Remove speed control vacuum reservoir, if equipped.
10. Disconnect oxygen sensor connector and harness clip.





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

CLEANING
1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.

INSPECTION
1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm. per 300 mm (0.006 in. per foot) of manifold length.
2. Inspect manifolds for cracks or distortion. Replace manifold as necessary

INSTALLATION
1. Position exhaust manifold and gasket in place.





2. Install exhaust manifold bolts and tighten in sequence shown 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. Install cylinder head cover (ULEV equipped).
7. Install speed control vacuum reservoir, if equipped.
8. Connect make-up air hose on cylinder head cover port.
9. Raise vehicle.
10. Install new flex joint to manifold flange gasket.
11. Attach exhaust system to manifold flange and tighten fasteners to 28 Nm (250 inch lbs.).
12. Install exhaust manifold support bracket and tighten fasteners (NLEV).
13. Install support bracket to cylinder block and exhaust manifold, if ULEV equipped. Snug all bolts first then tighten to 54 Nm (40 ft. lbs.).
14. Install bolt attaching wire harness heat shield to support bracket (NLEV), or exhaust manifold (ULEV).
15. Lower vehicle.
16. Connect negative cable to battery.