Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement
Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Raise and properly support the vehicle. Refer to Vehicle Lifting.





3. Disconnect the Heated Oxygen Sensor electrical connectors.
^ Disconnect the Heated Oxygen Sensor (H02S1) electrical connector (1).
^ Disconnect the Heated Oxygen Sensor (H02S) electrical connector (2).
4. Remove the exhaust pipe hangers (3).
5. Remove the following components from the exhaust manifold flange:
^ 2 bolts (4)
^ The springs (5)
6. Remove the exhaust manifold flange gasket.





7. Remove 1 bolt from the manifold support bracket to exhaust manifold.
8. Remove the upper heat insulator bolts.
9. Remove the upper heat insulator.





10. On 1.8L LNK engine, remove the 3 exhaust manifold bolts (1-3) and 2 exhaust manifold nuts (4-5).





11. On 1.8L LV6 engine, remove the exhaust manifold bolts (1-5).





12. On all engines, remove the following components:
^ The exhaust manifold
^ The exhaust manifold gasket
13. Remove the lower heat insulator bolts.
14. Remove the lower heat insulator.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.

1. Install the lower heat insulator to the exhaust manifold.
^ Tighten the lower heat insulator bolts to 18 Nm (13 ft. lbs.).
2. Install the following components:
^ The exhaust manifold gasket
^ The exhaust manifold.
3. On 1.8L LV6 engines, install the exhaust manifold bolts (1-5).
^ Tighten the exhaust manifold to nuts and bolts to 50 Nm (37 ft. lbs.).





4. On 1.8L LNK engines, install the 3 exhaust manifold bolts (1-3) and 2 exhaust manifold nuts (4-5).
^ Tighten the exhaust manifold to nuts and bolts to 50 Nm (37 ft. lbs.).
5. Install the upper heat insulator.





6. Install the upper heat insulator bolts.
^ Tighten the upper heat insulator bolts to 37 Nm (27 ft. lbs.).
7. Install 1 bolt to the manifold support bracket to exhaust manifold.
^ Tighten the manifold support bracket bolt 50 Nm (37 ft. lbs.).
8. Install the exhaust manifold flange gasket.





9. Install the following components to the exhaust manifold flange:
^ The springs (5)
^ 2 bolts (4)
^ Tighten the exhaust pipe bolts to 43 Nm (32 ft. lbs.).
10. Install the exhaust pipe hangers (3).
11. Connect the Heated Oxygen Sensor electrical connectors.
^ Connect the Heated Oxygen Sensor (H02S2) electrical connector (2).
^ Connect the Heated Oxygen Sensor (H02S1) electrical connector (1).
12. Lower the vehicle.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

13. Connect the negative battery cable.