Removal and Installation

REMOVAL
1. Disconnect battery negative cable.
2. Remove accessory drive belt. Refer to Accessory Drive section located in Engine for procedure.
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.

EGR Tube, Heated Oxygen Sensor And Generator/power Steering Strut:

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.

Heat Shield-Front:

13. Lower vehicle and remove screws attaching front heat shield to front manifold.

Crossover Pipe:

14. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head. Remove assemblies.
15. Inspect and clean manifold.

INSTALLATION
1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.).
2. Install generator.

NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. Replace if necessary.

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 new gaskets install front exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.).
6. Attach exhaust crossover with a new gasket and tighten fasteners to 54 Nm (40 ft. lbs.).
7. Connect up stream oxygen sensor connector.
8. Install exhaust system.
9. Attach exhaust pipe to exhaust manifold using new gasket and tighten bolts to 28 Nm (250 inch lbs.).
10. Connect down stream oxygen sensor connector
11. Install front manifold heat shield and tighten attaching screws to 12 Nm (105 inch lbs.).
12. Install accessory drive belt. Refer to Accessory Drive section located in Engine for procedure.
13. Connect battery negative cable.