Exhaust Manifold: Service and Repair

Exhaust Manifold Removal and Installation
Reference: Exhaust System Components

Removal

WARNING:
To avoid getting burned, do not work on exhaust system when it is hot. Exhaust system must be completely cool before beginning any service on it.

CAUTION:
Exhaust manifold has three-way catalytic converter which reduce harmful exhaust emissions.
Be careful not to drop exhaust manifold. If it is dropped, inside catalytic converter may be damaged on impact.

1) Disconnect negative (-) cable at battery.
2) Remove right and left side engine under covers.
3) Remove air cleaner assembly.
4) Remove condenser cooling fan.
^ Manual A/C model:
^ Auto A/C model:
5) Disconnect ground wire (1) and remove exhaust manifold cover (2).





6) Remove exhaust No. 1 pipe.
7) Disconnect A/F sensor connector (1).
8) Loosen exhaust manifold bolts and nuts in numerical order ("1" through "6") as shown in figure, and remove them.
9) Remove exhaust manifold (2), engine hook (3) and gasket from cylinder head.





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





2) Install exhaust manifold (1) and engine hook (2), and tighten exhaust manifold bolts and nuts to specified torque according to numerical order ("1" through "9") as shown as in figure.
Tightening torque
Exhaust manifold bolt* (a): 50 Nm (5.1 kg-m, 37.0 lbf-ft)
Exhaust manifold nut* (b): 50 Nm (5.1 kg-m, 37.0 lbf-ft)
3) Connect A/F sensor connector (3).





4) Install exhaust No. 1 pipe.
5) Install exhaust manifold cover (2) and connect ground wire (1).





6) Install condenser cooling fan.
^ Manual A/C model:
^ Auto A/C model:
7) Install air cleaner assembly.
8) Install right and left side engine under covers.
9) Connect negative (-) cable at battery.
10) Check exhaust system for exhaust gas leakage.