Exhaust Manifold: Service and Repair

REPLACEMENT
1. REMOVE ENGINE ASSEMBLY
2. Bank 1 sensor 1, bank 2 sensor 1: REMOVE HEATED OXYGEN SENSOR
3. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
a. Remove the 4 bolts and insulator.
4. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
a. Remove the 4 bolts and insulator.
5. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Remove the 8 nuts, manifold and gasket.
6. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Remove the 8 nuts, manifold and gasket.





7. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, measure the exhaust manifold's cylinder head contact surface for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the man if old.
8. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

HINT: Use the same procedures described for RH side.





9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.





b. Install the exhaust manifold with the 8 nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

HINT: Use the same procedures described for LH side.

11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
a. Install the insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
12. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
a. Install the insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
13. Bank 1 sensor 1, bank 2 sensor 1: INSTALL HEATED OXYGEN SENSOR
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
14. INSTALL ENGINE ASSEMBLY