Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement (Left)

Removal Procedure

1. Remove the air cleaner outlet duct from the throttle body.
2. Remove the air cleaner assembly.




3. Disconnect the engine coolant temperature (ECT) gauge sensor electrical connector.
4. Remove the intermediate steering shaft.
5. Disconnect the exhaust gas recirculation (EGR) valve inlet pipe from the exhaust manifold.




6. Remove the radiator inlet hose support bracket and nut.
7. Raise the vehicle.
8. Disconnect the exhaust pipe from the exhaust manifold.
9. Lower the vehicle to the proper height.
10. Remove the front tire to gain access to the rear exhaust manifold bolts.




11. Remove the fender wheelhouse extension.
12. Disconnect the spark plug wires from the spark plugs.




13. Remove the nuts holding the secondary air injection (AIR) pipe to the exhaust manifold, if equipped.
14. Remove the AIR pipe and gasket from the exhaust manifold.




15. Remove the exhaust manifold bolts and the stud.
16. Lower the vehicle.
17. Remove the exhaust manifold and the spark plug wire shields from the engine.
18. Clean all gasket surfaces.

Installation




1. Sub-assemble the spark plug wire shields, bolts, and NEW gaskets to the exhaust manifold.
The stud installs in the front hole.
2. Raise the vehicle to the proper height.
3. Install the exhaust manifold to the engine.
4. Connect the spark plug wires to the spark plugs.




5. Install the fender wheelhouse extension.
6. Install the front tire.




7. Install the AIR pipe and a NEW gasket to the exhaust manifold, if equipped.
8. Install the AIR pipe nuts.
Tighten the AIR pipe nuts to 25 N.m (18 lb ft).
9. Raise the vehicle.
10. Connect the exhaust pipe to the exhaust manifold.
11. Lower the vehicle.




12. Install the radiator inlet hose support bracket and nut.
Tighten the radiator inlet hose support bracket nut to 36 N.m (27 lb ft).




13. Connect the ECT gauge sensor electrical connector.
14. Connect the EGR valve inlet pipe to the exhaust manifold.
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N.m (22 lb ft).
15. Install the intermediate steering shaft.
16. Install the air cleaner assembly.
17. Install the air cleaner outlet duct to the throttle body.

Exhaust Manifold Replacement (Right)

Removal Procedure

1. Raise the vehicle.




2. Disconnect the exhaust pipe from the exhaust manifold.
3. Lower the vehicle.
4. Remove the bolt for the oil level indicator tube.
5. Disconnect the spark plug wires from the spark plugs.
6. Remove the nuts holding the secondary air injection (AIR) pipes to the exhaust manifold, if equipped.
7. Remove the AIR pipe and gasket.
8. Remove the exhaust manifold bolts.
9. Remove the exhaust manifold and the spark plug wire shields from the engine.
10. Clean all gasket surfaces.

Installation Procedure




1. Sub-assemble the spark plug wire shield, bolt, and NEW gaskets to exhaust manifold.
2. Install the exhaust manifold to the engine.
3. Connect the spark plug wires to spark plugs.




4. Install the AIR pipe and a NEW gasket to exhaust manifold, if equipped.
5. Install the air pipe nuts.
Tighten the AIR nuts to 25 N.m (18 lb ft).
6. Raise the vehicle.
7. Connect the exhaust pipe to the exhaust manifold.
8. Lower the vehicle.
9. Install the bolt for the oil level indicator tube.
Tighten the oil level indicator tube bolt to 12 N.m (106 lb in).