Exhaust Manifold Replacement Right Side

1. Disconnect the negative battery cable. Refer to

   Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

   in General Information.
2. Raise and suitably support the vehicle. Refer to SECTION 0A.
3. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
4. Remove the accessory drive belt. Refer to Drive Belt Replacement .



5. Remove the oil level indicator and tube.
6. Disconnect the oxygen sensor electrical connector.
7. Remove the three rear exhaust manifold bolts.
8. Lower the vehicle.



9. Remove the secondary air injection pipe fitting from the exhaust manifold.
10. Remove the EGR valve pipe. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.
11. Remove the generator and the rear lower brace. Refer to Rear Generator Brace in Engine Electrical.



12. Remove the remaining exhaust manifold studs and the bolts.
13. Remove the exhaust manifold and the exhaust manifold gasket.
14. Clean the exhaust manifold and the cylinder head sealing surfaces.

1. Install the exhaust manifold and gasket.
2. Install the front three exhaust manifold studs and the bolt.
3. Install the generator and the rear lower brace. Refer to Rear Generator Brace in Engine Electrical.
4. Raise and suitably support the vehicle. Refer to SECTION 0A.
5. Install the remaining exhaust manifold bolts.

Tighten
Tighten the exhaust manifold studs and the bolts to 40 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Connect the oxygen sensor electrical connector.



7. Install the oil level indicator and the oil level indicator tube.
8. Install the accessory drive belt. Refer to Drive Belt Replacement .
9. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
10. Lower the vehicle.
11. Install the EGR valve pipe. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls.



12. Install the secondary air injection pipe fitting to the exhaust manifold.

Tighten
Tighten the secondary air injection pipe fitting to 55 N·m (41 lb ft).

13. Connect the negative battery cable.

Exhaust Manifold Replacement Left Side

1. Disconnect the negative battery cable. Refer to

   Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

   in General Information.
2. Raise and suitably support the vehicle. Refer to SECTION 0A.
3. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
4. Lower the vehicle.
5. Remove the brake booster vacuum hose.



6. Remove the secondary air injection pipe fitting from the exhaust manifold.
7. Remove the accelerator control/cruise control servo cable adjuster. Refer to SECTION 5E.
8. Disconnect the oxygen sensor electrical connector.



9. Remove the exhaust manifold bolts.
10. Remove the exhaust manifold and the exhaust manifold gasket.
11. Clean the exhaust manifold and cylinder head sealing surfaces.

1. Install the exhaust manifold and gasket.
2. Install the exhaust manifold bolts.

Tighten
Tighten the exhaust manifold bolts to 40 N·m (30 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Connect the oxygen sensor electrical connector.
4. Install the accelerator control/cruise control servo cable adjuster. Refer to SECTION 5E2.



5. Install the secondary air injection pipe fitting to the exhaust manifold.

Tighten
Tighten the secondary air injection pipe fitting to 55 N·m (41 lb ft).

6. Install the brake booster vacuum hose.
7. Raise and suitably support the vehicle. Refer to SECTION 0A.
8. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
9. Connect the negative battery cable.