Exhaust Manifold: Service and Repair

FRONT EXHAUST MANIFOLD AND GASKET REPLACEMENT- L81

TOOLS REQUIRED
- J39194C 02 sensor wrench

REMOVAL





1. Disconnect front 02 sensor from connector at side of engine.
2. Remove front 02 sensor using 02 sensor wrench J39194C.





3. Remove coolant extension pipe and engine lift bracket bolt.
4. Remove oil level indicator and tube.





5. Remove upper exhaust manifold nuts to cylinder head.
6. Raise vehicle.





7. Remove front down pipe assembly.
8. Remove right hand splash shield.





IMPORTANT: Complete accessory drive belt (right hand mount) removal is not required. Only removal of belt from pulleys is required.

9. Loosen accessory drive belt from pulleys.





10. Disconnect electrical connector at A/C compressor and pressure transducer.





IMPORTANT: The A/C system will not need to be evacuated. The A/C compressor and lines will remain connected throughout this procedure.

11. Remove A/C compressor to A/C bracket bolts.
12. Remove A/C compressor and support with straps. Position compressor away from exhaust manifold assembly.





13. Remove exhaust manifold nuts.
14. Remove exhaust manifold assembly.
15. Remove exhaust manifold gasket.

INSTALLATION





1. Install new manifold gasket on cylinder head.
2. Install exhaust manifold.
3. Install exhaust manifold nuts.
Torque:
Exhaust Manifold Nuts - L81: 20 Nm (15 ft. lbs.)





4. Install front down pipe assembly.





5. Install A/C compressor to A/C bracket.
Torque:
A/C Compressor-to-Bracket Bolt L81: 22 Nm (16 ft. lbs.)
6. Connect electrical connector at A/C compressor and pressure transducer.





7. Install accessory drive belt around pulleys.
8. Install right hand splash shield.
9. Lower vehicle.





10. Install oil level indicator and tube.
Torque:
Coolant Extension Pipe/Engine Lift Bracket Bolt -L81: 20 Nm (15 ft. lbs.)





IMPORTANT: Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound such as Permatex 77124, Saturn P/N 21485279 (or equivalent). Never use silicon products; silicon products will cause damage to oxygen sensor.

11. Install 02 sensor into exhaust manifold.
Torque:
Oxygen Sensor-to-Exhaust Manifold Pipe - L81: 45 Nm (33 ft. lbs.)
12. Connect 02 sensor electrical connector at side of engine. Assure connector is fully retained to bracket.