Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement

^ Tools Required
- J 39194-C 02 Sensor Remover Tool

Removal Procedure





1. Disconnect the Intake Air Temperature (IAT) sensor connector.
2. Loosen the clap at the air cleaner assembly.
3. Remove the push-pin attachment from the outlet resonator/duct assembly to support the bracket.
4. Loosen the clamp at the throttle body assembly.
5. Disconnect the PCV fresh air vent hose at the cam cover.
6. Remove the outlet resonator/duct assembly.





7. Remove the exhaust manifold heat shield bolts.
8. Remove the exhaust manifold heat shield.
9. Disconnect the front and rear 02 sensor connectors. Remove the sensor if the exhaust manifold is being replaced using J 39194-C.
10. Raise the vehicle.





11. Remove the exhaust manifold pipe to manifold nuts.
12. Remove the exhaust manifold pipe to resonator pipe nuts behind the converter.
13. Disconnect the rear 02 sensor wire from the heat shield.
14. Separate the exhaust manifold pipe and resonator pipe. Discard the gaskets.





15. Remove the exhaust manifold nuts.
16. Remove the exhaust manifold assembly and discard the gasket.





17. Remove the exhaust manifold gasket and discard.

Installation Procedure





1. Install a new manifold gasket on the cylinder head.





2. Install the exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the exhaust manifold nuts.
^ Tighten the exhaust manifold-to-cylinder head nuts L61 to 18 Nm (13 ft. lbs.).
4. If necessary, transfer the 02 sensor from the old manifold.

Important: Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound such as Permatex 77124, SA P/N 21485279 or equivalent.

5. Install the 02 sensor into the exhaust manifold.
^ Tighten the 02 sensor to 45 Nm (33 ft. lbs.).





6. Install the gasket and exhaust pipe to the intermediate pipe.
7. Install the exhaust pipe-to-intermediate pipe nuts.
^ Tighten the exhaust pipe-to-intermediate pipe nuts L61 to 30 Nm (22 ft. lbs.).
8. Attach the rear 02 sensor wire to the heat shield.





9. Install a new exhaust manifold gasket onto the exhaust manifold flange studs.
10. Position the exhaust manifold pipe onto the exhaust manifold studs and install the exhaust manifold nuts.
^ Tighten the exhaust manifold pipe-to-exhaust manifold nuts L61 to 42 Nm (31 ft. lbs.).





11. Lower the vehicle.
12. Install the exhaust manifold heat shield.
13. Install the exhaust manifold heat shield bolts.
^ Tighten the exhaust manifold heat shield bolts L61 to 23 Nm (17 ft. lbs.).





14. Install the outlet resonator/duct assembly into position.
15. Connect the PVC fresh air vent hose assembly.
16. Tighten the clamp at the throttle body assembly.
17. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
18. Tighten the air cleaner assembly.
19. Connect the Intake Air Temperature (IAT) sensor connector.