Exhaust Manifold Replacement - Front

Exhaust Manifold Replacement (Front - L81)

^ Tools Required
- J 39194-C Oxygen Sensor Wrench
- SA 9105E Engine Support Fixture (3 Bar)

Removal Procedure





1. Disconnect the exhaust manifold heated oxygen sensor electrical connection.
2. Remove the exhaust manifold heated oxygen sensor using the J 39194-C.





3. Drain the coolant.





4. Remove the upper radiator hose from the coolant extension housing.






Important: The powertrain must be lifted up in order to remove the coolant extension housing.

5. Install the SA9105E and support the powertrain.





6. Remove the front transaxle mount through bolt.





7. Raise the powertrain with the engine support fixture to provide clearance to pull the extension housing above the coolant module.
8. Remove the oil level indicator tube and coolant extension tube bolt.
9. Remove the oil level indicator by pulling upwards.





10. Twist the coolant extension housing to remove.





11. Remove the power steering pipe bracket bolt.
12. Remove the upper exhaust manifold nuts.





13. Disconnect the front exhaust manifold pipe heated oxygen sensor electrical connection.

Caution: Refer to Vehicle Lifting.

14. Raise the vehicle.
15. Remove the front exhaust manifold pipe to exhaust manifold nuts.





16. Remove the front exhaust manifold pipe to rear exhaust manifold pipe bolts.
17. Remove the front exhaust manifold pipe assembly.





18. Remove the oil filter housing assembly.





19. Remove the lower exhaust manifold nuts.
20. Remove the exhaust manifold and gasket.

Installation Procedure





1. Install the exhaust manifold and new gasket.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the lower exhaust manifold nuts.
^ Tighten the exhaust manifold nut to 20 Nm (15 ft. lbs.).





3. Install the oil filter housing to block.
^ Tighten the oil filter cartridge housing-to-engine to 45 Nm (33 ft. lbs.).
4. Install the oil filter cap and filter to housing.
^ Tighten the oil filter cap to 15 Nm (11 ft. lbs.).





5. Install the front exhaust manifold pipe assembly and gaskets.

Important: Do not tighten the fasteners.

6. Install the front exhaust manifold pipe to rear exhaust manifold pipe bolts.





7. Install the front exhaust manifold pipe to exhaust manifold nuts.
^ Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 Nm (25 ft. lbs.).
8. Tighten the front exhaust manifold pipe to rear exhaust manifold pipe bolts.
^ Tighten the exhaust manifold pipe bolts to 20 Nm (15 ft. lbs.).






Notice: Always use a pickle-based anti-seize compound Saturn P/N 21485279 (or equivalent) on the threads of the Heated Oxygen Sensor (H02S-2). If the H02S-2 is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicone products. Silicone products will damage the sensor.

9. Install the front exhaust manifold pipe heated oxygen sensor.
^ Tighten the oxygen sensors (lower exhaust pipe) to 45 Nm (33 ft. lbs.).
10. Lower the vehicle.
11. Connect the front exhaust manifold pipe heated oxygen sensor electrical connection.





12. Install the upper exhaust manifold nuts.
^ Tighten the exhaust manifold nut to 20 Nm (15 ft. lbs.).
13. Install the power steering pipe bracket bolt.
^ Tighten the power steering pipe bracket bolt to 8 Nm (71 inch lbs.).





14. Install 2 new O-rings onto the coolant extension housing.
15. Lubricate the O-rings with coolant and install the extension housing.
16. Install the oil level indicator tube and coolant extension housing bolt.
^ Tighten the coolant extension housing bolt to 20 Nm (15 ft. lbs.).





17. Lower the powertrain and align the front transaxle mount and mounting bracket using the engine support fixture.





18. Install the front transaxle mount through bolt.
^ Tighten the transaxle mount through bolt to 55 Nm (41 ft. lbs.).





19. Remove the SA9105E, or equivalent.





20. Install the upper radiator hose.





21. Refill the coolant.





22. Install the exhaust manifold heated oxygen sensor using the J 39194-C.
^ Tighten the oxygen sensors (exhaust manifold) to 50 Nm (37 ft. lbs.).
23. Connect the exhaust manifold heated oxygen sensor electrical connection.
24. Start the vehicle and check for coolant and exhaust leaks.