Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement (1.6L Engine)

Removal Procedure





Caution: Refer to Hot Exhaust System Caution in Service Precautions.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Disconnect the heated oxygen sensor (HO2S1) electrical connector.
3. Remove the following from the exhaust manifold:
- 2 nuts
- 3 bolts
- The upper exhaust manifold heat shield (1)
4. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





5. Remove the following from the exhaust manifold and engine block:
- 2 bolts
- 1 nut
- The exhaust manifold reinforcement bracket (1)





6. Remove the following from the exhaust manifold (1):
- 2 bolts
- The front pipe/three way catalytic converter (TWC) assembly (3)
7. Lower the vehicle.





8. Remove the 9 nuts and the lift hook from the exhaust manifold (3).





9. Remove the exhaust manifold (3) with the gasket (2).





10. Remove the three bolts and lower the exhaust manifold heat shield (6) from the exhaust manifold (2).
11. Remove the heated oxygen (HO2S1) Sensor (4) from the exhaust manifold (23.
12. Remove the three way catalytic converter (TWC) front pipe gasket from the exhaust manifold (2).

Installation Procedure





Notice: Refer to Fastener Notice in Service Precautions.

1. Install the heated oxygen (HO2S1) sensor (4) into the exhaust manifold (2).
- Tighten the (HO2S1) Sensor to 43 Nm (32 ft. lbs.).
2. Install the 3 bolts and lower the exhaust manifold heat shield (6) to the exhaust manifold (2).
- Tighten the lower manifold heat shield bolts to 10 Nm (89 inch lbs.).





3. Install the new exhaust manifold gasket (2) and the exhaust manifold (3).





4. Install the engine hanger (3) to the cylinder head. Secure the exhaust manifold and hanger with 9 nuts(1).
- Tighten the exhaust manifold nuts to 23 Nm (17 ft. lbs.).
5. Raise and support the vehicle. Refer to Vehicle Lifting.





6. Install the front pipe/TWC assembly (3) with a new gasket (2) to the exhaust manifold (1). Secure the assembly with 2 bolts.
- Tighten the exhaust manifold-to-front pipe/TWC assembly bolts to 50 Nm (37 ft. lbs.).





7. Install the exhaust manifold brackets (1) to the exhaust manifold and the engine block. Secure the brackets with 1 nut and 2 bolts.
- Tighten the engine mount-to-exhaust bracket bolts to 54 Nm (40 ft. lbs.).
- Install the exhaust bracket-to-exhaust manifold nut to 50 Nm (37 ft. lbs.).
8. Lower the vehicle.





9. Install the upper exhaust manifold heat shield (1) to the exhaust manifold. Secure the heat shield with 2 nuts and 3 bolts.
- Tighten the upper exhaust manifold heat shield nuts and bolts to 10 Nm (89 inch lbs.).
10. Connect the (HO2S1) electrical connector.
11. Connect the negative battery cable.
- Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).