Exhaust Manifold Pipe Replacement L81

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

1. Hoist the vehicle.

Important: Do not apply silicone products to the oxygen sensor.

2. Disconnect the electrical connector from the oxygen sensor (O2S).



3. Remove the exhaust pipe flange to front exhaust manifold nuts (3).
4. Remove the exhaust pipe crossover flange nuts (2).




Important: Hold the link stud from rotating when removing nut. Discard the used nuts.

5. Remove the left and right lower stabilizer link to stabilizer nuts.



6. Remove the right side stabilizer bar to cradle bolts.
7. Rotate the stabilizer bar upward to provide clearance for the exhaust pipe removal.



8. Separate the downpipe from the exhaust pipe, twist/rotate to clear the rear flange and remove.
9. Fully remove and discard the used gaskets.
10. Remove the oxygen sensor if transferring to a new exhaust pipe.

Notice: Excessive flexing of the exhaust pipe may damage the flex coupling. Limit flexing to 12 degrees.

1. Position pipe into vehicle, and install new gasket onto manifold studs.
2. Assemble exhaust pipe to manifold, install new nuts and hand tighten only.



3. Install the new gasket onto the exhaust pipe rear flange.

Notice: Refer to Fastener Notice in the Preface section.




4. Assemble the front pipe to rear pipe, install the nuts and tighten.

Tighten
Tighten the front pipe-to-rear pipe nuts - L81 to 30 N·m(22 lb ft).

5. Tighten the front pipe to manifold nuts.

Tighten
Tighten the front pipe-to-manifold nuts - L81 to 42 N·m (31 lb ft).

Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize compound that does not contain silicone.




6. Install the oxygen sensor and tighten.

Tighten
Tighten the oxygen sensor - L81 to 45 N·m (33 lb ft).




7. Pull the stabilizer bar into position, install the mounting bolts and tighten.

Tighten
Tighten the stabilizer bar mounting bolt - L81 to 50 N·m (37 lb ft).




8. Position the lower stabilizer link to stabilizer bar. Install new nuts and tighten.

Tighten
Tighten the stabilizer bar-to-stabilizer link nut - L81 to 65  (48 lb ft).

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

Notice: Excessive flexing of the exhaust pipe may damage the flex coupling. Limit flexing to 12 degrees.

1. Hoist the vehicle.




Important: Do not apply silicon products to the oxygen sensor.

2. Disconnect the electrical connector from the oxygen sensor (O2S).



3. Remove the exhaust pipe flange to rear exhaust manifold nuts (3).



4. Remove the exhaust pipe flange to intermediate pipe nuts (3).



5. Separate the hanger from the rubber isolator.
6. Separate the flange from the studs, and remove the rear exhaust pipe.
7. Remove the oxygen sensors if transferring to new exhaust pipes.

1. Position the pipe into the vehicle front and rear flanges and install a new gasket onto the manifold studs.



2. Assemble the exhaust pipe to manifold and install new nuts -- hand tighten only.



3. Install the new gasket onto the exhaust pipe rear flange.
4. Assemble the front pipe to rear pipe, install the nuts and tighten.

Tighten
Tighten the front pipe-to-rear pipe nuts - L81 to 30 N·m (22 lb ft).

5. Tighten the front pipe to manifold nuts.

Tighten
Tighten the front pipe-to-maniold nuts - L81 to 42 N·m(31 lb ft).





Notice: Silicone based products will contaminate the HO2S. Use only a nickel based anti-seize compound that does not contain silicone.

6. Install the oxygen sensor and tighten, connect the electrical connector.

Tighten
tighten the oxygen sensor - L81 to 45 N·m (33 lb ft).

Exhaust Manifold Pipe Replacement L61

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

Notice: Excessive flexing of the exhaust pipe may damage the flex coupling. Limit flexing to 12 degrees.

1. Raise the vehicle on hoist.

Important: Do not apply silicon products to the oxygen sensor.

2. Disconnect the electrical connector from the oxygen sensor (O2S).



3. Remove the nuts (3) from the exhaust pipe flange to intermediate pipe and separate the flange from the studs.



4. Remove the nuts (3) from the exhaust pipe flange to exhaust manifold.



5. Separate the hanger from the rubber isolator.
6. Separate the pipe flange from the manifold studs and remove the exhaust pipe.
7. Fully remove and discard used gaskets.
8. Remove the oxygen sensor if transferring to a new exhaust pipe.

1. Install a new gasket onto the exhaust manifold studs.
2. Assemble the exhaust pipe to manifold. Install new nuts and tighten.

Tighten
Tighten the exhaust manifold pipe-to-exhaust manifold nuts - 4-CYL to 42 N·m (31 lb ft).




3. Install the new gasket onto the exhaust pipe flange.
4. Assemble the exhaust pipe to intermediate pipe. Install new nuts and tighten.

Tighten
Tighten the exhaust pipe-to-intermediate pipe nuts - 4-CYL to 30 N·m (22 lb ft).