Exhaust Manifold: Service and Repair

Fig. 18 Exhaust manifold assembly. Except turbocharged engine:

EXCEPT TURBOCHARGED & EFI ENGINES

1. Disconnect battery ground cable.
2. Remove air cleaner.
3. Disconnect electrical connector from fan switch.
4. Remove radiator shroud bolts, then the shroud.
5. Disconnect EGR tube from exhaust manifold.
6. Disconnect thermactor tube from exhaust manifold.
7. Remove A/C hose bracket, if equipped.
8. Remove exhaust manifold heat stove.
9. Remove exhaust manifold attaching nuts, Fig. 18.
10. Raise and support vehicle.
11. Remove anti-roll brace.
12. Disconnect water tube mounting brackets.
13. Disconnect exhaust pipe from exhaust manifold.
14. Remove exhaust manifold.
15. Reverse procedure to install.

Fig. 18 Exhaust manifold assembly. Except turbocharged engine:

TURBOCHARGED & EFI ENGINES

1. Disconnect battery ground cable.
2. Remove cooling fan shield from radiator support.
3. Loosen compressor outlet hose clamp from throttle housing.
4. Disconnect hose from turbocharger compressor inlet.
5. Remove alternator and bracket assembly.
6. Disconnect EGO sensor electrical connector, Fig. 19.
7. Raise and support vehicle.
8. Disconnect oil supply line from turbocharger coolant outlet.
9. Disconnect oil return line from cylinder block.
10. Remove exhaust pipe to turbocharger assembly attaching nuts, then position exhaust pipe away from mounting studs.
11. Remove exhaust shield from water outlet connector.
12. Remove nuts attaching exhaust manifold to cylinder head. Slide exhaust manifold and turbocharger assembly away from cylinder head.
13. Remove turbocharger and exhaust manifold as an assembly. If exhaust manifold is being replaced, replace EGO sensor.
14. Reverse procedure to install. Torque exhaust manifold nuts to 16---19 ft. lbs.