Exhaust Manifold Replacement - Rear

Exhaust Manifold Replacement (Rear - L81)

^ Tools Required
- J 39194-C 02 Sensor Wrench

Removal Procedure





1. Disconnect the exhaust manifold heated oxygen sensor electrical connection.
2. Remove the exhaust manifold heated oxygen sensor using the J39194-C.
3. Remove the EGR pipe.

Important: Do not apply grease or silicon products to the Heated Oxygen Sensor (H02S-2). Do not alter the wiring in any way. The wires carry air reference to the sensor.

4. Disconnect the rear exhaust manifold pipe heated oxygen sensor electrical connection.





5. Remove the rear exhaust manifold pipe heat shield.





6. Remove the rear exhaust manifold pipe heated oxygen sensor.

Caution: Refer to Vehicle Lifting.

7. Raise the vehicle on a hoist.





8. Remove the rear exhaust manifold pipe to front exhaust manifold pipe attachment bolts.





9. Remove the rear exhaust manifold pipe to resonator bolts.
10. Remove the rear exhaust manifold pipe assembly from the vehicle.
11. Remove the exhaust manifold nuts.
12. Remove the exhaust manifold and gasket.

Installation Procedure





1. Install the exhaust manifold and the new gasket.

Notice: Refer to Fastener Notice in Service Precautions.

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





3. Install the rear exhaust manifold pipe assembly and gaskets.

Important: Do not tighten the fasteners.

4. Install the exhaust manifold to rear exhaust manifold pipe nuts.





5. Install the front exhaust manifold pipe to rear exhaust manifold pipe attachment bolts.
^ Tighten the exhaust manifold pipe bolts to 20 Nm (15 ft. lbs.).





6. Install the rear exhaust manifold pipe to resonator bolts.
^ Tighten the exhaust manifold pipe bolts to 20 Nm (15 ft. lbs.).





7. Tighten the rear exhaust manifold pipe to exhaust manifold nuts.
^ Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 Nm (25 ft. lbs.).
8. Lower the vehicle.
9. Install the EGR pipe to the exhaust manifold and EGR flange.
^ Tighten the EGR pipe bolts to 25 Nm (18 ft. lbs.).






Notice: Always use a pickle-based anti-seize compound Saturn/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.

10. Install the heated oxygen sensor using the J 39194-C.
^ Tighten the oxygen sensors (exhaust manifold) to 50 Nm (37 ft. lbs.).
11. Connect the rear exhaust manifold pipe heated oxygen sensor electrical connections.





12. Install the exhaust manifold pipe heat shield.
^ Tighten the exhaust manifold pipe heat shield bolts to 8 Nm (71 inch lbs.).
13. Start the vehicle and inspect for exhaust leaks.