Exhaust Manifold - Removal

REMOVAL

EXHAUST MANIFOLD - LEFT SIDE





CAUTION: Steering column module is centered to the vehicle's steering system. Failure to keep the system and steering column module centered and locked/inhibited from rotating can result in steering column module damage.

1. Lock the steering wheel in the center position Refer to Clockspring Centering Clockspring Assembly / Spiral Cable.
2. Remove the engine cover and resonator Air Cleaner Housing.
3. Remove the battery (5) and battery tray (7) Battery Tray.





4. Disconnect the electrical connector (2) at the EVAP canister purge solenoid.
5. Remove EVAP canister purge solenoid (1) from mounting bracket by lifting straight up and position aside.





6. Remove the Power Distribution Center (PDC) (1) and the Integrated Power Module (IPM) (2) and position aside Power Distribution Module.





7. Remove the right side strut tower support beam retaining nuts (1).





8. Remove the left side strut tower support beam retaining nuts (1).





9. Rotate the strut tower support beam forward and remove beam.

CAUTION: Use caution when connecting, disconnecting or repositioning any wiring harness. Damage could occur to the wiring harness due to vehicle mileage, vehicle age and environmental conditions.

10. Disconnect the remaining connectors from the main harness and position aside.
11. Remove the upper mounting bolt from the dipstick tube.





12. Remove the coupling pinch bolt (1) at the intermediate steering shaft (2) to the rack and pinion assembly (3).
13. Remove the front two exhaust manifold heat shield nuts.





14. Raise and support the vehicle.
15. Remove the left front wheelhouse splash shield (2) Front Fender Liner.
16. Remove any skid plates (if equipped).
17. Reposition any wiring harnesses as needed.





18. Remove the intermediate steering shaft (1) and support bracket (2) Steering Shaft.





19. Remove the battery ground harness retaining nut (2) located in front of the starter (1) and position harness aside.
20. Remove the lower stud/bolt (3) from the dipstick tube.





21. Remove the two rear exhaust manifold heat shield retaining nuts (1).
22. Saturate the front exhaust pipe/catalytic converter retaining bolts and nuts with heat valve lubricant and allow 5 minutes for penetration.
23. Remove the right and left exhaust pipe/catalytic converter assembly Catalytic Converter.
24. Lower the vehicle.





25. Using the sequence shown, remove the eight bolts/studs from the exhaust manifold.






NOTE: The exhaust manifold is removed from below the engine compartment.

26. Raise and support the vehicle.
27. Remove the exhaust manifold (2) and gasket from the vehicle.
28. Inspect the exhaust manifold (2) for any damage Exhaust Manifold - Inspection.
29. Clean the mating surfaces (1, 2).

EXHAUST MANIFOLD - RIGHT SIDE





1. Partially drain the engine coolant Service and Repair.
2. Remove the engine cover.
3. Remove the air box assembly (2) and resonator Air Cleaner Housing.
4. Disconnect and isolate the negative battery cable.





5. Remove the coolant recovery bottle (1) Coolant Reservoir.

CAUTION: Use caution when connecting, disconnecting or repositioning any wiring harness. Damage could occur to the wiring harness due to vehicle mileage, vehicle age and environmental conditions.

6. Disconnect the upper right side engine harness and position aside.
7. If required, disconnect the heater hoses from the heater core tubes in the engine compartment and position aside.





8. Raise and support the vehicle.
9. Remove the right front wheelhouse splash shield (left side shown, right side similar) Front Fender Liner.
10. Remove any skid plates (if equipped).
11. Disconnect and remove the upstream O2 sensor to the exhaust pipe/catalytic converter assembly Oxygen Sensor.
12. Saturate the front exhaust pipe/catalytic converter assembly bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
13. Remove the right and left exhaust pipe/catalytic converter assembly Catalytic Converter.
14. Lower the vehicle.
15. Remove the right side exhaust manifold heat shield.





16. Using the sequence shown, remove the eight bolts/studs from the exhaust manifold.

NOTE: The exhaust manifold is removed from below the engine compartment.

17. Raise and support the vehicle.
18. Remove the exhaust manifold and gasket from the vehicle.
19. Inspect the exhaust manifold for any damage Exhaust Manifold - Inspection.
20. Clean the mating surfaces.