Exhaust Manifold Replacement - Left Side A28NET

1. Remove the battery tray. Refer to Battery Tray Replacement.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
4. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Drain the cooling system. Refer to Cooling System Draining and Filling.
7. Lower the vehicle.



8. Remove the catalytic converter front heat shield (1).



9. Remove the transmission heat shield (1).
10. Remove the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement.
11. Remove the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement.
12. Remove the secondary air injection inlet pipe. Refer to LINK.
13. Remove the generator. Refer to Generator Replacement.
14. Remove the secondary air injection pump. Refer to Secondary Air Injection Pump Replacement.
15. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.



16. Remove the turbocharger coolant feed pipe (1).



17. Remove the 4 exhaust front manifold heat shield fasteners (1).
18. Remove the exhaust front manifold heat shield (2).



19. Remove the 3 exhaust manifold brace fasteners (1).



20. Remove the exhaust turbocharger inlet pipe fasteners (1).
21. Remove the exhaust turbocharger inlet pipe (2).



22. Remove the 2 secondary air injection pipe fasteners (1).



23. Remove the 7 exhaust front manifold fasteners (1).
24. Remove the exhaust front manifold (2).
25. Remove the exhaust front manifold gasket (3).
26. Clean all of the gasket surfaces.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the NEW exhaust front manifold gasket (3).
2. Install the exhaust front manifold (2).
3. Install the 7 exhaust front manifold fasteners (1) and tighten to 25 N·m (18 lb ft).



4. Install a NEW secondary air injection pipe gasket.
5. Install the 2 secondary air injection pipe fasteners (1) and tighten to 10 N·m (89 lb in).



6. Install a NEW exhaust turbocharger inlet pipe gasket.
7. Install the exhaust turbocharger inlet pipe (2).
8. Install the exhaust turbocharger inlet pipe fasteners (1) and tighten to 30 N·m (22 lb ft).



9. 9. Install the 3 exhaust manifold brace fasteners (1) and tighten to 30 N·m (22 lb ft).



10. Install the exhaust front manifold heat shield (2).
11. Install the 4 exhaust front manifold heat shield fasteners (1) and tighten to 10 N·m (89 lb in).



12. Install the turbocharger coolant feed pipe (1) and tighten M12 to 30 N·m (22 lb ft) and M14 to 35 N·m (26 lb ft).
13. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
14. Install the secondary air injection pump. Refer to Secondary Air Injection Pump Replacement.
15. Install the generator. Refer to Generator Replacement.
16. Install the secondary air injection inlet pipe. Refer to LINK.
17. Install the secondary air injection outlet pipe. Refer to Secondary Air Injection Pump Pipe Replacement.
18. Install the charge air cooler outlet air tube. Refer to Charge Air Cooler Outlet Air Tube Replacement.



19. Install the transmission heat shield (1).



20. Install the catalytic converter front heat shield (1).
21. Raise the vehicle.
22. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.
23. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
25. Install the battery tray. Refer to Battery Tray Replacement.
26. Fill the cooling system. Refer to Cooling System Draining and Filling.