Exhaust Manifold: Service and Repair

Exhaust Manifold Removal and Installation

Removal

WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down.

1. Disconnect negative cable at battery.
2. Disconnect heated oxygen sensor coupler (1).





3. Remove exhaust manifold upper cover (2).





4. Remove exhaust No.1 pipe nut (1).
5. Remove engine under cover (right side).
6. Remove exhaust pipe No.2 stiffener (1).





7. Remove exhaust No.1 pipe (2).
8. Remove air cleaner case with air cleaner outlet hose.
9. Disconnect electric lead wire (1) couplers (heated oxygen sensor and A/C magnet clutch) and release clamps (2).
10. Remove air cleaner case bracket (3).





11. Support engine with engine support jack and remove engine RH mounting No.1 bracket (4).





12. Remove engine RH mounting bracket (1).





13. Remove exhaust manifold (1) and its gasket (2) from cylinder head.

NOTE: Be careful not to damage fins of radiator.

Installation





1. Install new gasket to cylinder head.





2. Install exhaust manifold (1).
Tighten manifold bolt and nuts to specified torque.
Tightening torque
(a): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)





3. Install engine RH mounting bracket (1).
Tighten bracket bolts to specified torque.
Tightening torque
Engine RH mounting bracket bolts (a): 55 Nm (5.5 kgf-m, 40.0 ft. lbs.)
4. Install engine RH mounting No.1 bracket (1).
Tighten bolts and nut to specified torque.
Tightening torque
Engine RH mounting No.1 bracket bolts and nut (a): 55 Nm (5.5 kgf-m, 40.0 ft. lbs.)





5. Install air cleaner case bracket (2).
6. Install air cleaner case with air cleaner outlet hose.
7. Install pipe gasket and exhaust No 1 pipe (2).
Before installing pipe gasket, check it for deterioration or damage, and replace as necessary
Tighten exhaust pipe nuts and bolts to specified torque
Tightening torque
Exhaust manifold to No.1 pipe nuts (a):: 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
Exhaust No.1 pipe to No.2 pipe bolts (b):: 43 Nm (4.3 kgf-m, 31.5 ft. lbs.)





8. Install exhaust pipe No 2 stiffener (3).
Tighten exhaust pipe No.2 stiffener bolts to specified torque
Tightening torque
Exhaust pipe No.2 stiffener bolts (c): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
9. Install engine under cover (Right side).
10. Install exhaust manifold upper cover (1).





11. Connect heated oxygen sensor coupler (2).
12. Connect negative cable at battery.
13. Check exhaust system for exhaust gas leakage.