Exhaust Manifold: Service and Repair

1. Disconnect battery ground cable and drain coolant from engine.
2. Disconnect accelerator cable.
3. Remove air cleaner assembly and heat stove duct from heat shield.
4. Disconnect all vacuum lines from intake manifold.
5. Remove thermactor belt from pulley, thermactor hose and thermactor pump from engine.
6. Remove exhaust pipe to exhaust manifold nuts and disconnect exhaust pipe from exhaust manifold.
7. Remove exhaust manifold heat shield.
8. Disconnect Exhaust Oxygen (EGO) sensor electrical connector.
9. Disconnect thermactor check valve hose from tube assembly. Remove EGR valve bracket nuts and EGR valve bracket.
10. Disconnect water inlet hose from intake manifold.
11. Disconnect EGR hose from EGR valve.
12. Remove intake manifold and gasket from engine.
13. Remove exhaust manifold from engine.

Exhaust Manifold Replacement:

14. Reverse procedure to install. Torque exhaust manifold bolts in sequence shown to 7-10 Nm (5-7 ft lb) and then to 27-41 Nm (20-30 ft lb).

Fig. 5 Intake Manifold Bolt Tightening Sequence:

15. Torque intake manifold bolts in sequence to 20-30 Nm (15-22 ft lb).