Exhaust Manifold: Service and Repair

REMOVAL





1. Raise vehicle squarely on a lift. Refer to lift instructions for positioning vehicle.

WARNING: Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. Make sure hoist does not contact fuel or brake lines.





2. Remove front exhaust pipe-to-exhaust manifold fasteners, lower front exhaust pipe, remove gasket and discard.
3. Lower vehicle.
4. Remove the A/C compressor and the rear compressor bracket. See Heating and Air Conditioning.





5. Remove the two front exhaust pipe to engine stiffening bracket fasteners.





6. Disconnect electrical connector at the oxygen sensor.

NOTE: Use a 19 mm, 6 point crows foot to remove the oxygen sensor, if required.

7. Remove the exhaust manifold attachment nuts.
8. Remove the exhaust manifold and gasket. Discard the gasket.
9. Inspect the exhaust manifold to front exhaust pipe flange for warpage.

INSTALLATION
1. Install new exhaust manifold gasket with smooth side toward the exhaust manifold.





2. Install the exhaust manifold and attachment nuts.





3. In sequence, torque the exhaust manifold attachment nuts. Torque to 31 Nm (23 ft. lbs.).





4. Connect the electrical connector at the oxygen sensor. Push in until a click is heard and pull back to ensure a positive engagement.

CAUTION: Whenever the oxygen sensor is removed, coat the threads with a nickel based anti-seize such as Saturn P/N 21485279 (or equivalent). If the oxygen sensor is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Do not use an anti-seize that contains silicone. Torque Oxygen Sensor to 45 Nm (33 ft. lbs.).

5. Install the A/C compressor rear bracket and the A/C compressor. See Heating and Air Conditioning. Torque front/rear brackets-to-head/block to 25 Nm (19 ft.lbs.). Torque compressor-to-front bracket 54 Nm (40 ft. lbs.). Torque compressor-to-rear bracket 25 Nm (19 ft. lbs.).
6. Raise vehicle squarely on a lift. Refer to lift instructions for positioning vehicle.
7. Install new exhaust pipe-to-manifold gasket on the studs.
8. Install and torque the exhaust pipe-to-manifold attachment fasteners. Torque to 31 Nm (23 ft. lbs.).
9. Install the two front exhaust pipe-to-engine stiffener bracket fasteners and clamp, if removed. Torque Front Exhaust Pipe Support Bracket-to-Engine Stiffener Bracket. Torque to 31 Nm (23 ft. lbs.). Torque Clamp-to-Front Exhaust Pipe and Support Bracket. Torque to 60 Nm (44 ft. lbs.).
10. Lower vehicle and check for leaks.