Removal and Installation
REMOVAL1. Disconnect battery negative cable.
2. Remove accessory drive belt.
3. Remove generator.
4. Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at flex-joint.
5. Disconnect down stream oxygen sensor connector.
6. Lower exhaust system to gain access to rear manifold.
7. Separate EGR tube from rear manifold and disconnect Heated Oxygen Sensor lead wire.
8. Remove heat shield from rear engine mount.
9. Remove Generator/Power Steering Support Strut.
10. Remove bolts attaching crossover pipe to manifold.
11. Disconnect up stream oxygen sensor connector.
12. Remove bolts attaching rear manifold to cylinder head and remove manifold.
13. Lower vehicle and remove screws attaching front heat shield to front manifold.
14. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head. Remove assemblies.
15. Inspect and clean manifold. Refer to Cleaning and Inspection outlined in this section for procedures.
INSTALLATION
1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.).
2. Install generator.
3. Using new gasket attach crossover pipe to exhaust manifold and tighten bolts to 54 Nm (40 ft. lbs.) and connect oxygen sensor lead.
4. Install EGR Tube and Generator/Power Steering Strut.
5. Using a new gaskets install front exhaust manifold and attach exhaust crossover tighten to 54 Nm (40 ft. lbs.).
6. Connect up stream oxygen sensor connector.
7. Install exhaust system.
8. Attach exhaust pipe to exhaust manifold using new gasket and tighten bolts to 28 Nm (250 inch lbs.).
9. Connect down stream oxygen sensor connector.
10. Install front manifold heat shield and tighten attaching screws to 12 Nm (105 inch lbs.).
11. Install accessory drive belt.
12. Connect battery negative cable.