Exhaust Manifold: Service and Repair

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





3. Disconnect the upstream H02S electrical connector mounted on the cooling fan shroud.

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.





4. Remove the (A) five nuts and remove the (B) exhaust manifold shield.





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





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





7. Pivot the generator forward.
1 Loosen the lower bolt.
2 Remove the upper bolt.
3 Pivot the generator forward.





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





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

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

INSTALLATION





















1. Follow the Removal Procedure in reverse order.

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