Exhaust Manifold Replacement L61

1. Remove the connector position assurance (CPA) retainer (1).
2. Disconnect the heated oxygen sensor (HO2S) electrical connector (2).




Important: The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

3. Remove the HO2S.



4. Remove the exhaust manifold heat shield bolts.
5. Remove the heat shield.
6. Remove the intermediate pipe. Refer to Catalytic Converter Replacement .



7. Remove and discard the exhaust manifold nuts.
8. Remove the exhaust manifold/catalytic converter assembly.
9. Remove and discard the exhaust manifold gasket.

1. Install a NEW exhaust manifold gasket on the cylinder head.
2. Install the exhaust manifold/catalytic converter assembly.
3. Install the exhaust manifold nuts finger tight.

Notice: Refer to Fastener Notice in the Preface section.




4. Tighten the exhaust manifold nuts in the sequence shown.

Tighten
Tighten the nuts to 14 N·m (10 lb ft).

5. Install the intermediate pipe. Refer to Catalytic Converter Replacement .



6. Install the heat shield.
7. Install the exhaust manifold heat shield bolts.

Tighten
Tighten the bolts to 23 N·m (17 lb ft).




8. Install the HO2S.

Tighten
Tighten the sensor to 42 N·m (31 lb ft).




9. Connect the HO2S electrical connector.
10. Install the CPA retainer (1).
11. Start the vehicle and inspect for leaks.