Exhaust Manifold: Service and Repair

Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Raise and support the vehicle. Refer to Vehicle Lifting.





3. Remove the two bolts and the front pipe/Three Way Catalytic Converter (TWC) assembly (4) from the exhaust manifold, or the Warm Up Catalytic Converter (WU/TWC) (3) if equipped.
4. Lower the vehicle.





5. Disconnect the Heated Oxygen Sensor (H02S 1) electrical connector (1).
6. Remove the Heated Oxygen Sensor (H02S 1).
7. Remove the three bolts and the exhaust manifold heat shield from the exhaust manifold.
8. Remove the following from the exhaust manifold:
^ The four bolts
^ The three nuts
^ The engine hanger
9. Remove the exhaust manifold (2).
10. Remove the exhaust manifold gasket from the cylinder head.

Installation Procedure





1. Install the new exhaust manifold gasket (2) to the cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the exhaust manifold (1). Secure the manifold with the engine hanger, four bolts and three nuts.
Tighten the exhaust manifold bolts and nuts to 23 Nm (17 ft. lbs.).
3. Install the exhaust manifold heat shield to the exhaust manifold (1). Secure the exhaust manifold heat shield with the three bolts.
Tighten the heat shield bolts to 15 Nm (11 ft. lbs.).
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Install the front pipe/TWC (4), or the Warm Up/TWC assembly (3) to the exhaust manifold with a new seal. Secure the assembly with the two bolts.
Tighten the exhaust manifold-to-front pipe/TWC assembly bolts to 45 Nm (33 ft. lbs.).





6. Lower the vehicle.
7. Install the Heated Oxygen Sensor (H02S 1).
Tighten the Heated Oxygen Sensor (H02S 1) to 40 to 50 Nm (29 to 36 ft. lbs.).
8. Connect the H02S 1 electrical connector (1).
9. Connect the negative battery cable.
10. Check the exhaust system for exhaust gas leakage.