Exhaust Manifold: Service and Repair

REMOVAL
1. Disconnect the battery negative cable.
2. Drain the cooling system.
3. Raise the vehicle.
4. Disconnect the exhaust pipe from the engine exhaust manifold.
5. Lower the vehicle.
6. Remove intake manifold.





7. Remove fasteners 2 through 5 and remove the intake manifold.
8. Remove fasteners 1, 6 and 7 and remove the engine exhaust manifold.

CLEANING
Clean mating surfaces on cylinder head and manifold, wash with solvent and blow dry with compressed air.

INSPECTION
Inspect manifold for cracks, Inspect mating surfaces of manifold for flatness with a straight edge. Seal surfaces must be flat within 0.1 mm (0.004 inch) overall.

INSTALLATION
1. Clean the intake and engine exhaust manifolds and cylinder head mating surfaces. DO NOT allow foreign material to enter either the intake manifold or the ports in the cylinder head.
2. Install a new intake manifold gasket over the alignment dowels on the cylinder head.





3. Install the engine exhaust manifold assembly. Exhaust manifold must be centrally located over the end studs and spacer.
4. Tighten bolt No.1 to 41 Nm (30 ft. lbs.) torque.
5. Install the intake manifold on the cylinder head dowels .
6. Install bolts 2 through 5. Tighten these bolts to 31 Nm (23 ft. lbs.) torque.
7. Install new engine exhaust manifold spacers over the engine exhaust manifold mounting studs in the cylinder head.
8. Tighten nuts 6 and 7 to 23 Nm (17 ft. lbs.) torque.
9. Install the intake manifold.
10. Raise the vehicle.
11. Connect the exhaust pipe to the engine exhaust manifold. Tighten the bolts to 31 Nm (23 ft. lbs.) torque.
12. Lower the vehicle.
13. Refill cooling system.
14. Connect the battery negative cable.
15. Start the engine and check for leaks.