Exhaust Manifold Replacement - Right Side HSV CSV VXR8
Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.
Caution: Refer to Protective Goggles and Glove Caution in the Preface section.
- Disconnect the battery ground cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection.
- Remove the engine dress cover. Refer to
Engine Cover Replacement.
- Remove the oil level indicator tube. Refer to
Oil Level Indicator and Tube Removal.
- Remove the right side spark plug wires. Refer to
Spark Plug Wire Replacement.
- Remove the right side spark plugs from the cylinder head. Refer to
Spark Plug Replacement.
- Remove the right side catalytic converter. Refer to
Catalytic Converter Replacement - Right Side.
- Loosen the exhaust manifold to cylinder head retaining
bolts (1) working from the outside to the centre.
Important: Bolts with micro-encapsulated thread sealant
must be discarded after removal.
- Remove the exhaust manifold to cylinder head retaining bolts (1).
Discard the bolts.
Important: Make sure that the surrounding wiring harness
and electrical connectors are not damaged when removing the exhaust manifold (2).
Important: The exhaust manifold gasket (1) and
sealing ring (3) are single use parts. They must be discarded after removal.
Important: The right hand exhaust manifold can only
be removed upwards out of the engine bay.
- Remove the exhaust manifold (2).
Discard the exhaust manifold
gasket (1) and sealing ring (3).
Installation Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.
- Before installation inspect for the following:
• | Damage to the gasket sealing surfaces. |
• | Distortion of exhaust manifold mating surface. |
• | Damage to the exhaust mounting holes. |
- Check for distortion on the mating surface of the
exhaust manifold (1) by using a straight edge (2) and a feeler gauge (3).
- Clean the exhaust manifold and catalytic converter flange mating surfaces.
- Install a NEW exhaust manifold gasket (1) and
a NEW sealing ring (3) onto the exhaust manifold (2).
Notice: Refer to Exhaust System Inspection Notice in the Preface section.
- Install the exhaust manifold assembly to engine.
Notice: Refer to Fastener Notice in the Preface section.
Important: Do not fully tighten the exhaust manifold
to cylinder head retaining bolts (1) at this stage.
- Install the NEW exhaust manifold to cylinder head retaining bolts (1).
Do not fully tighten at this stage.
- Clean the threads of the exhaust manifold to catalytic converter retaining
studs with a suitable cleaning solvent.
- Tighten the exhaust manifold to cylinder head retaining bolts (1)
working from the centre to the outside.
Tighten
Tighten the bolts to 20 Nm (15 lb ft).
Important: Make sure the sealing ring is seated correctly.
- Install the right side catalytic converter. Refer to
Catalytic Converter Replacement - Right Side
- Install the right side spark plugs to the cylinder head. Refer to
Spark Plug Replacement.
- Install the right side spark plug wires. Refer to
Spark Plug Wire Replacement.
- Install the oil level indicator tube. Refer to
Oil Level Indicator and Tube Installation.
- Install the engine dress cover. Refer to
Engine Cover Replacement.
- Connect the battery ground cable to the battery. Refer to
Battery Negative Cable Disconnection and Connection.
Exhaust Manifold Replacement - Right Side 3.6L Engine NT3
Removal Procedure
- Disconnect the battery ground cable from the battery. Refer to
Battery Negative Cable Disconnection and Connection.
- Remove the engine dress cover. Refer to
Engine Cover Replacement.
Caution: Refer to Exhaust Service Caution in the Preface section.
Caution: Refer to Protective Goggles and Glove Caution in the Preface section.
- Remove the exhaust manifold heat shield to exhaust manifold retaining bolts (1).
- Remove the exhaust manifold heat shield (2).
Important: The right catalytic converter to exhaust
manifold retaining nuts (3) are single use parts. They must be discarded after
removal.
- Remove the right catalytic converter to exhaust manifold retaining nuts (3).
Discard the nuts.
- Remove the right catalytic converter. Refer to
Catalytic Converter Replacement - Right Side.
- Lower the vehicle.
- Loosen the exhaust manifold to cylinder head retaining
bolts (1) working from the outside to the centre.
Important: Bolts with micro-encapsulated thread sealant
must be discarded after removal.
- Remove the exhaust manifold to cylinder head retaining bolts (1).
Discard the bolts.
Important: Make sure that the surrounding wiring harness
and electrical connectors are not damaged when removing the exhaust manifold (2).
Important: The exhaust manifold gasket (1) and
sealing ring (3) are single use parts. They must be discarded after removal.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Remove the exhaust manifold (2).
Discard the exhaust
manifold gasket (1) and sealing ring (3).
Installation Procedure
Notice: Refer to Exhaust Service Caution in the Preface section.
- Before installation inspect for the following:
• | Damage to the gasket sealing surfaces. |
• | Distortion of exhaust manifold mating surface. |
• | Damage to the exhaust mounting holes. |
- Check for distortion on the mating surface of the
exhaust manifold (3) by using a straight edge (1) and a feeler gauge (2).
- Clean the exhaust manifold and catalytic converter flange mating surfaces.
- Install a NEW exhaust manifold gasket (1) and
NEW sealing ring (3) to the exhaust manifold (2).
Notice: Refer to Exhaust System Inspection Notice in the Preface section.
- Install the exhaust manifold assembly to the engine.
Important: Do not fully tighten the exhaust manifold
to cylinder head retaining bolts (1) at this stage.
- Install the NEW exhaust manifold to cylinder head retaining bolts (1).
Do not fully tighten at this stage.
Important: Make sure the sealing ring is seated correctly.
- Install the right catalytic converter. Refer to
Catalytic Converter Replacement - Right Side.
Notice: Refer to Fastener Notice in the Preface section.
- Install the NEW right catalytic converter to exhaust manifold retaining nuts (3).
Tighten
Tighten the nuts to 45 N·m (33 lb ft).
- Tighten the exhaust manifold to cylinder head retaining
bolts (1) working from the centre to the outside.
Tighten
Tighten the bolts to 20 N·m (15 lb ft).
- Install the exhaust manifold heat shield (2).
- Install the exhaust manifold heat shield to exhaust manifold retaining
bolts (1).
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Install the engine dress cover. Refer to
Engine Cover Replacement.
- Connect the battery ground cable to the battery. Refer to
Battery Negative Cable Disconnection and Connection.
Exhaust Manifold Replacement - Right Side 3.6L Engine NT4
Removal Procedure
Caution: Refer to Exhaust Service Caution in the Preface section.
Caution: Refer to Protective Goggles and Glove Caution in the Preface section.
- Ignition OFF.
Caution: Refer to Battery Disconnect Caution in the Preface section.
- Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Remove the engine cover. Refer to
Engine Cover Replacement.
- Remove the right pre-catalytic convertor heated oxygen sensor (HO2S).
Refer to
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
- Remove the exhaust manifold heat shield. Refer to
Exhaust Manifold Heat Shield Replacement - Right Side
.
- Remove the right catalytic converter. Refer to
Catalytic Converter Replacement - Right Side
.
Important: Bolts with micro-encapsulated thread sealant
must be discarded after removal.
- Remove the exhaust manifold to cylinder head retaining bolts (1).
Discard the bolts.
Caution: Refer to Safety Glasses Caution in the Preface section.
Caution: Refer to Vehicle Lifting Caution in the Preface section.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
Important: Bolts with micro-encapsulated thread sealant
must be discarded after removal.
- Remove the exhaust manifold to cylinder head retaining bolts (1).
Discard the bolts.
Important: Make sure that the surrounding wiring harness
and electrical connectors are not damaged when removing the exhaust manifold (2).
Important: The exhaust manifold gasket (1) and
sealing ring (3) are single use parts. They must be discarded after removal.
- Remove the exhaust manifold (2) from the engine assembly.
- Separate the exhaust manifold (2) from the exhaust manifold gasket (1)
and sealing ring (3).
- Discard the exhaust manifold gasket (1) and sealing ring (3).
Installation Procedure
- Inspect the exhaust manifold before installation. Refer to
Exhaust Manifold Cleaning and Inspection - Right Side.
- Install a NEW exhaust manifold gasket (1) and
NEW sealing ring (3) to the exhaust manifold (2).
Caution: Refer to Safety Glasses Caution in the Preface section.
Caution: Refer to Vehicle Lifting Caution in the Preface section.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
Important: A suitable support must be used to support
the exhaust manifold while the vehicle is being lowered.
- Install the exhaust manifold assembly (2) to the engine.
Important: Do not fully tighten the exhaust manifold
to cylinder head retaining bolts (1) at this stage.
- Install NEW exhaust manifold to cylinder head retaining bolts (1).
Caution: Refer to Fastener Caution in the Preface section.
- Tighten the exhaust manifold to cylinder head retaining bolts (1) working
from the centre to the outside.
Tighten
Tighten the bolts to 20 N·m (15 lb ft).
- Lower the vehicle.
Important: Do not fully tighten the exhaust manifold
to cylinder head retaining bolts (1) at this stage.
- Install NEW exhaust manifold to cylinder head retaining bolts (1).
Caution: Refer to Fastener Caution in the Preface section.
- Tighten the exhaust manifold to cylinder head retaining bolts (1) working
from the centre to the outside.
Tighten
Tighten the bolts to 20 N·m (15 lb ft).
- Install the right catalytic converter. Refer to
Catalytic Converter Replacement - Right Side
.
- Install the exhaust manifold heat shield. Refer to
Exhaust Manifold Heat Shield Replacement - Right Side
.
- Install the right pre-catalytic convertor HO2S. Refer to
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
.
- Install the engine cover. Refer to
Engine Cover Replacement.
- Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection
.
Exhaust Manifold Replacement - Right Side 6.0L Engine
Removal Procedure
Warning: Refer to Exhaust Service Warning in the Preface section.
Warning: Refer to Protective Goggles and Glove Warning in the Preface section.
- Ignition OFF.
Warning: Refer to Battery Disconnect Warning in the Preface section.
- Disconnect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Remove the engine cover. Refer to
Engine Cover Replacement.
- Remove the oil level indicator tube. Refer to
Oil Level Indicator Tube Replacement.
- Remove the right side spark plug leads. Refer to
Spark Plug Wire Replacement.
- Remove the right side spark plugs from the cylinder head. Refer to
Spark Plug Replacement.
- Remove the right side exhaust manifold heat shield. Refer to
Exhaust Manifold Heat Shield Replacement - Right Side.
Note: The right catalytic converter
to exhaust manifold retaining nuts (1) are single use parts. They must be discarded
after removal.
- Remove the right catalytic converter to exhaust
manifold retaining nuts (1).
Discard the nuts.
- Disconnect the right catalytic converter (4) from the exhaust manifold (3).
- Loosen the exhaust manifold to cylinder head retaining bolts (2)
working from the outside to the centre.
Note: Bolts with micro-encapsulated thread sealant
must be discarded after removal.
- Remove the exhaust manifold to
cylinder head retaining bolts (2).
Discard the bolts.
Note: Make sure that the surrounding
wiring harness and electrical connectors are not damaged when removing the exhaust
manifold (2).
Note: The exhaust manifold
gasket (1) and sealing ring (3) are single use parts. They must be discarded
after removal.
- Remove the exhaust manifold (2).
Discard the exhaust manifold gasket (1) and sealing ring (3).
Installation Procedure
- Clean and inspect the exhaust manifold. Refer to
Exhaust Manifold Cleaning and Inspection.
- Install NEW exhaust manifold gasket (1) and
NEW sealing ring (3) to the exhaust manifold (2).
Caution: Refer to Exhaust System Inspection Caution in the Preface section.
- Install the exhaust manifold assembly to engine.
- Install the NEW exhaust manifold to cylinder head
retaining bolts (1).
- Tighten the exhaust manifold to cylinder head retaining bolts (2)
working from the centre to the outside to
20 N·m (15 lb ft).
Note: Make sure the sealing ring is seated correctly.
- Lift the right catalytic converter (4) up and forward to
connect to the exhaust manifold (3).
- Clean the threads of the exhaust manifold to catalytic converter retaining
studs with a suitable cleaning solvent.
Caution: Refer to Fastener Caution in the Preface section.
- Install the NEW right catalytic converter to exhaust manifold retaining nuts (1)
and tighten to
45 N·m (33 lb ft)
- Install the right side exhaust manifold heat shield. Refer to
Exhaust Manifold Heat Shield Replacement - Right Side.
- Install the right side spark plugs to the cylinder head. Refer to
Spark Plug Replacement.
- Install the right side spark plug leads. Refer to
Spark Plug Wire Inspection.
- Install the oil level indicator tube. Refer to
Oil Level Indicator Tube Replacement.
- Install the engine cover. Refer to
Engine Cover Replacement.
- Connect the battery negative cable. Refer to
Battery Negative Cable Disconnection and Connection.