Exhaust Manifold: Service and Repair

Exhaust Manifold Removal and Installation

WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down.

Removal
1. Disconnect negative cable at battery.
2. Disconnect heated oxygen sensor coupler (3) and release it from bracket (4).
3. Remove exhaust manifold upper cover (1) and lower cover.





4. Remove heated oxygen sensor-1 (2) from exhaust manifold.





5. Remove exhaust No. 1 pipe nut (1).
6. Remove engine under cover (Right side).
7. Remove heated oxygen sensor-2 from exhaust No. 1 pipe.
8. Remove exhaust pipe front No. 1 (3) and No.2 stiffeners (4).





9. Remove exhaust No. 1 pipe (1).
10. Remove air cleaner case with air cleaner outlet hose.
11. Detach P/S fluid reservoir from body.
12. Disconnect electric lead wire (1) couplers (heated oxygen sensor and A/C magnet clutch) and release clamps (2).





13. Support engine with engine support jack and remove engine RH mounting (3).





14. Remove engine RH mounting bracket (1).





15. Remove exhaust manifold (1) and its gasket (2) from cylinder head.

NOTE: Be careful not to damage fins of radiator.

Installation





1. Install new gasket (1) to cylinder head.





2. Install exhaust manifold (1).
Tighten manifold bolt and nuts to specified torque.
Tightening torque
Exhaust manifold bolt and nut (a): 50 Nm (5.0 kg-m, 36.5 ft. lbs.)





3. Install engine RH mounting bracket (1).
Tighten bracket bolts to specified torque.
Tightening torque
Engine RH mounting bracket bolt (a): 55 Nm (5.5 kg-m, 40.0 ft. lbs.)





4. Install engine RH mounting (1).
Tighten bolts, and nut to specified torque.
Tightening torque
Engine RH mounting bolt and nut (a): 55 Nm (5.5 kg-m, 40,0 ft. lbs.)
5. Install air cleaner case with air cleaner outlet hose.
6. Install pipe gasket and exhaust No. 1 pipe (2).
Before installing pipe gasket, check it for deterioration or damage, and replace as necessary.
Tighten exhaust pipe nuts and bolts to specified torque.
Tightening torque
Exhaust No.1 pipe bolt and nut (a): 43 Nm (4.3 kg-m, 31.5 ft. lbs.)





7. Install exhaust pipe front No.1 (4) and No.2 stiffeners (5).
8. Install heated oxygen sensor-2 to exhaust No.1 pipe.
Tightening torque
Heated oxygen sensor-2: 45 Nm (4.5 kg-m, 33.0 ft. lbs.)
9. Install engine under cover (Right side).





10. Install heated oxygen sensor-1 (1).
Tightening torque
Heated oxygen sensor-2 (a): 45 Nm (4.5 kg-m, 33.0 ft. lbs.)
11. Install exhaust manifold upper cover (1) and lower cover.





12. Connect heated oxygen sensor coupler (3) and clamp its wire securely.
13. Connect negative cable at battery.
14. Check exhaust system for exhaust gas leakage.