Exhaust Manifold Replacement - Right

Exhaust Manifold Replacement Right

^ Tools Required
- J 42640 Steering Column Lock Pin

Removal Procedure

Caution: Refer to Hot Exhaust System Caution in Service Precautions.

Caution: Refer to Exhaust Parts Removal Caution in Service Precautions.





1. Disconnect the heated oxygen sensor at the sensor pigtail.

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

2. Lock the steering column by installing the J 42640 into the underside of the steering column.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Remove the rear exhaust manifold pipe.





5. Remove the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).
6. Remove the secondary AIR tube (1) and the gasket from the exhaust manifold (3). Do not reuse the gasket.





7. Disconnect the post heated oxygen sensor wiring harness retainer from the power steering gear heat shield.
8. Remove the two bolts securing the heat shield.
9. Remove the heat shield from the power steering gear.





10. Remove the rearward nut (3) securing the vehicle speed sensor heat shield (1).
11. Loosen the forward nut (2) in order to remove the heat shield (1).
12. Remove the heat shield (1) from the transaxle.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.





13. Remove the intermediate shaft pinch bolt.
14. Disconnect the intermediate shaft from the steering gear.





15. Remove the nut securing the right engine mount to the right engine mount bracket.





16. Remove the nut securing the left transaxle mount to the left transaxle mount bracket.





17. Support the rear of the engine frame with a tall screw jack
18. Remove the four rearward engine frame-to-body bolts.
19. Lower the screw jack approximately 4 cm (1.5 inch) allowing the rear of the engine frame to lower.
20. Remove the heated oxygen sensor if replacement is necessary.





21. Remove the right exhaust manifold retaining nuts.
22. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
23. Clean and inspect the right exhaust manifold.

Installation Procedure





1. Place a NEW exhaust manifold gasket over the cylinder head studs.
2. Position the right exhaust manifold to the right cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the right exhaust manifold nuts.
^ Tighten the exhaust manifold nuts to 25 Nm (18 ft. lbs.).
4. Install the heated oxygen sensor.





5. Raise the engine cradle into position.
6. Install the four rearward engine frame-to-body bolts.
^ Tighten the engine frame bolts to 191 Nm (141 ft. lbs.).
7. Remove the screw jack.





8. Install the nut securing the left transaxle mount to the left transaxle mount bracket.
^ Tighten the transaxle mount nut to 80 Nm (59 ft. lbs.).





9. Install the nut securing the right engine mount to the right engine mount bracket.
^ Tighten the engine mount nut to 80 Nm (59 ft. lbs.).

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control, which could result in personal injury.





10. Connect the intermediate shaft to the steering gear.
11. Install the intermediate shaft pinch bolt.
^ Tighten the intermediate shaft pinch bolt to 45 Nm (33 ft. lbs.).





12. Position the vehicle speed sensor heat shield (1) to the studs on transaxle.
13. Install the retaining nuts (2, 3) securing the vehicle speed sensor heat shield to the transaxle.
^ Tighten the vehicle speed sensor heat shield nuts to 50 Nm (37 ft. lbs.).





14. Position the power steering gear heat shield to the power steering gear.
15. Install the two bolts securing the heat shield.
^ Tighten the power steering gear heat shield bolts to 9 Nm (79 inch lbs.).
16. Connect the post heated oxygen sensor wiring harness retainer to the heat shield.





17. Install the new gasket to the secondary AIR tube (1).
18. Install the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).
^ Tighten the secondary AIR tube nuts to 12 Nm (106 inch lbs.).
19. Install the rear exhaust manifold pipe.
20. Lower the vehicle.





21. Remove the J 42640 from the steering column.
22. Connect the heated oxygen sensor at the sensor pigtail.