12. Exhaust Manifold Removal - Left with RPO NC1 or NF7

Exhaust Manifold Removal - Left (With RPO NC1 or NF7)





1. Remove the A.I.R. valve pipe nuts from the exhaust manifold.
2. Remove the A.I.R. valve bolt from the mounting bracket.
3. Remove the A.I.R. valve nuts from the mounting bracket.
4. Remove the A.I.R. valve.

Important: DO NOT reuse the old A.I.R. valve pipe gasket.

5. Remove and discard the A.I.R. valve pipe gasket.





6. Remove the oxygen sensor (1) and inspect the sensor for excessive deposits or damage. Replace the oxygen sensor if necessary.





7. Remove the exhaust manifold to crossover pipe bolts (3).
8. Remove the exhaust manifold bolts (6).
9. Remove the exhaust manifold (2).

Important: DO NOT reuse the exhaust manifold to crossover pipe gasket.

10. Remove and discard the exhaust manifold to crossover pipe gasket (5).

Important: DO NOT reuse the exhaust manifold gasket.

11. Remove and discard the exhaust manifold gasket (1).





12. Disconnect the EGR inlet tube nut (1) from the exhaust crossover.

Important: The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

13. Remove the EGR inlet pipe bolt (2) and flange (3) from the water crossover.
14. Remove the EGR inlet tube and discard.





15. Remove the exhaust crossover stud (3) and bolt (1).
16. Remove the exhaust crossover (2).





17. If equipped, remove the left coolant heater (1) as follows:
17.1. Remove the coolant heater bolt.
17.2. Remove the coolant heater from the cylinder block.

Exhaust Manifold Removal - Right (W/O RPO, NC1 or NF7)





1. Remove the oxygen sensor (1) and inspect the sensor for excessive deposits or damage. Replace the oxygen sensor if necessary.

Notice: The stud must be reinstalled in the original location. The stud may remain attached to the nut when initially removed during exhaust manifold removal. In order to prevent exhaust leakage between the exhaust manifold and cylinder head the nut and stud combination must be reinstalled during exhaust manifold installation in the original location.





2. Remove the right exhaust manifold retaining nuts (3).

Important: DO NOT reuse the exhaust manifold gasket.

3. Remove the exhaust manifold and the gasket (1).





4. If equipped, remove the right coolant heater (1) as follows:
4.1. Remove the coolant heater retaining bolt.
4.2. Remove coolant heater from the cylinder block.