Exhaust Manifold Removal and Installation

Exhaust Manifold Removal and Installation

Exhaust System Components

Removal

CAUTION:

Touching a hot exhaust system component will cause a burn.

Do not perform any service work on the exhaust system until the exhaust system is cool.

NOTE:

Applying a shock to the exhaust manifold may cause damage to the three-way catalytic converter inside the exhaust manifold.

Handle the exhaust manifold carefully. Be careful not to drop it or hit it against something.

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





6) Remove exhaust No.1 pipe. Exhaust Pipe and Muffler Removal and Installation
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): 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
Exhaust manifold nut* (b): 55 Nm (5.6 kgf-m, 40.5 lbf-ft)

3) Connect A/F sensor connector (3).





4) Install exhaust No.1 pipe. Exhaust Pipe and Muffler Removal and Installation
5) Install exhaust manifold cover (2) and connect ground wire (1).





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