Exhaust Manifold: Service and Repair

REMOVAL

1. Disconnect the battery ground cable.
2. Remove the drive belt.

CAUTION: When repairing the exhaust system or removing exhaust components, disconnect the heated oxygen sensor (H02S) at the wiring harness to prevent damage to the sensors and harness.





3. Disconnect the upstream H02S electrical connector mounted on the cooling fan shroud.
4. Remove the five nuts and remove the exhaust manifold shield.





5. Remove the two exhaust gas recirculation (EGR) tube to exhaust manifold nuts and studs.





6. Remove the (A) three bolts and position the (B) power steering pressure hose and bracket aside.





7. Pivot the generator forward.
A) Loosen the lower bolt.
B) Remove the upper bolt.
C) Pivot the generator forward.





8. Remove the four exhaust manifold-to-three way catalytic converter (TWC) nuts.

CAUTION:
Aluminum Components
Do not work on aluminum engine components until the engine is cold.

9. Remove the eight exhaust manifold nuts and carefully remove the exhaust manifold and gasket. Discard the gasket.

INSTALLATION

CAUTION:
Cleaning Aluminum Surfaces
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.

To install, reverse the removal procedure.
- Tighten the exhaust manifold nuts to 20-24 Nm (14.7-17.7 ft. lbs.).
- Tighten TWC nuts to 34-47 Nm (26-34 ft. lbs.).
- Tighten Install and tighten upper generator bolt to 40-55 Nm (29-40 ft. lbs.).
- Tighten Tighten the lower generator bolt to 20-30 Nm (15-22 ft. lbs.).
- Tighten power steering pressure hose bolts to 7.8-10.8 Nm (64-87 inch lbs.).
- Tighten exhaust manifold shield nuts to 5-7 Nm (45-61 inch lbs.).
- Tighten EGR tube nuts to 5-7 Nm (44.6-62 inch lbs.).
- Tighten the negative battery cable to 5-7 Nm (44.6-62 inch lbs.).