Exhaust Manifold Pipe Replacement - Front

Exhaust Manifold Pipe Replacement Front

Removal Procedure

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

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





1. Remove the rear exhaust manifold pipe.
2. Remove the transaxle assembly.
3. Remove the two bolts attaching the left exhaust manifold to the front exhaust manifold pipe.





4. Remove the bolt (1) securing the front exhaust manifold pipe (2) to the crankcase.
5. Remove the nut securing the coil cassette ground wire to the cylinder head.
6. Remove the bolt (3) securing the front exhaust manifold pipe (2) to the cylinder head.

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

7. Disconnect the EGR inlet pipe nut from the front exhaust manifold pipe (2).
8. Remove the front exhaust manifold pipe (2).
9. Remove the front exhaust manifold pipe seal from the left exhaust manifold. Do not reuse the seal.
10. Remove the exhaust manifold flange retainer.

Installation Procedure

Notice: Refer to Exhaust System Clearance Notice in Service Precautions.





1. Place the retainer and a NEW front exhaust manifold pipe seal over the left exhaust manifold.
2. Insert the front exhaust manifold pipe (2) around the left exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the bolts (1, 3) securing the front exhaust manifold pipe (2) to the engine.
^ Tighten the front exhaust manifold pipe support bolts to 25 Nm (18 ft. lbs.).
4. Install the nut securing the coil cassette ground wire to the cylinder head.
^ Tighten the coil cassette ground wire nut to 17 Nm (13 ft. lbs.).





5. Install the two bolts securing the front exhaust manifold pipe to the left exhaust manifold.
^ Tighten the front exhaust manifold pipe bolts to 25 Nm (18 ft. lbs.).
6. Hand start the EGR inlet pipe nut to the front exhaust manifold pipe to prevent cross threading.
^ Tighten the EGR inlet pipe nut to 60 Nm (44 ft. lbs.).
7. Install the transaxle assembly.
8. Install the rear exhaust manifold pipe.