Exhaust Manifold Replacement - Front

REMOVAL AND INSTALLATION FRONT EXHAUST MANIFOLD REPLACEMENT

^ TOOLS REQUIRED
- J39194C O2 Sensor Wrench
- J43405 Engine Support Fixture Adapter
- SA9105E Engine Support Fixture (3 Bar)

REMOVAL





1. Disconnect exhaust manifold oxygen sensor electrical connection.
2. Remove exhaust manifold oxygen sensor using O2 Sensor Wrench J39194C.





3. Drain coolant.





4. Remove upper radiator hose from coolant extension housing.





5. Install Engine Support Fixture (3 Bar) SA9105E and Engine Support Fixture Adapter J43405 and support powertrain.

IMPORTANT: The powertrain must be lifted up in order to remove the coolant extension housing.





6. Remove front transaxle mount through bolt.





7. Raise powertrain with engine support fixture to provide clearance to pull extension housing above coolant module.
8. Remove oil level indicator tube and coolant extension tube bolt.
9. Remove oil level indicator tube by pulling upwards.





10. Twist coolant extension housing to remove.





11. Remove power steering pipe bracket bolt.
12. Remove upper exhaust manifold nuts.





13. Disconnect front exhaust manifold pipe oxygen sensor electrical connection.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST.

14. Raise vehicle.
15. Remove front exhaust manifold pipe to exhaust manifold nuts.





16. Remove front exhaust manifold pipe to rear exhaust manifold pipe bolts.
17. Remove front exhaust manifold pipe assembly.





18. Remove oil filter housing assembly.





19. Remove lower exhaust manifold nuts.
20. Remove exhaust manifold and gasket.

INSTALLATION





1. Install exhaust manifold and new gasket
2. Install lower exhaust manifold nuts.
Torque:
Exhaust Manifold Nut: 20 Nm (15 ft. lbs.)





3. Install oil filter housing to block.
Torque:
Oil Filter Cartridge Housing-to Engine: 45 Nm (33 ft. lbs.)
4. Install oil filter cap and filter to housing.
Torque:
Oil Filter Cap: 15 Nm (11 ft. lbs.)





5. Install front exhaust manifold pipe assembly and gaskets.

NOTICE: Do not tighten fasteners.

6. Install front exhaust manifold pipe to rear exhaust manifold pipe bolts.





7. Install front exhaust manifold pipe to exhaust manifold nuts.
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 Nm (25 ft. lbs.)
8. Tighten front exhaust manifold pipe to rear exhaust manifold pipe bolts.
Torque:
Exhaust Manifold Pipe Bolts: 20 Nm (15 ft. lbs.)

NOTICE: Always use a nickel-based anti-seize compound Saturn P/N 21485279 (or equivalent) on the threads of the oxygen sensor. If the oxygen sensor is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicon product; silicon products will cause damage to oxygen sensor.





9. Install front exhaust manifold pipe oxygen sensor.
Torque:
Oxygen Sensors (Lower Exhaust Pipe): 45 Nm (33 ft. lbs.)
10. Lower vehicle.
11. Connect front exhaust manifold pipe oxygen sensor electrical connection.





12. Install upper exhaust manifold nuts.
Torque:
Exhaust Manifold Nut: 20 Nm (15 ft. lbs.)
13. Install power steering pipe bracket bolt.
Torque:
Power Steering Pipe Bracket Bolt: 8 Nm (71 inch lbs.)





14. Install two new O-rings onto coolant extension housing.
15. Lubricate O-ring with coolant and install extension housing.
16. Install oil level indicator tube and coolant extension housing bolt.
Torque:
Coolant Extension Housing Bolt: 20 Nm (15 ft. lbs.)





17. Lower powertrain and align front transaxle mount and mounting bracket using engine support fixture.





18. Install front transaxle mount through bolt.
Torque:
Transaxle Mount Through Bolt: 55 Nm (41 ft. lbs.)





19. Remove engine support fixture and adapters SA9150E and J43405 (or equivalent).





20. Install upper radiator hose.





21. Refill coolant.





22. Install exhaust manifold oxygen sensor using O2 sensor wrench J39194C.
Torque:
Oxygen Sensors (Exhaust Manifold): 50 Nm (37 ft. lbs.)
23. Connect exhaust manifold oxygen sensor electrical connection.
24. Start vehicle and check for coolant and exhaust leaks.