Exhaust Manifold Replacement - Right Side

Exhaust Manifold Replacement - Right Side

Removal Procedure

Warning:
Refer to Exhaust Service Warning Exhaust Service Warning.


Warning:
Refer to Protective Goggles and Glove Warning Protective Goggles and Glove Warning.


1. Ignition OFF.

Warning:
Refer to Battery Disconnect Warning Battery Disconnect Warning.


2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

3. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement Oil Level Indicator Tube Replacement.

4. Remove the right side spark plug leads. Refer to Spark Plug Wire Replacement Service and Repair.

5. Remove the right side spark plugs from the cylinder head. Refer to Spark Plug Replacement Service and Repair.

6. Remove the right side exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side.





Note:
The right catalytic converter to exhaust manifold retaining nuts (1) are single use parts. They must be discarded after removal.

7. Remove the right catalytic converter to exhaust manifold retaining nuts (1).

Discard the nuts.

8. Disconnect the right catalytic converter (4) from the exhaust manifold (3).

9. Loosen the exhaust manifold to cylinder head retaining bolts (2) working from the outside to the centre.

Note:
Bolts with micro-encapsulated thread sealant must be discarded after removal.

10. Remove the exhaust manifold to cylinder head retaining bolts (2).

Discard the bolts.





Note:
Make sure that the surrounding wiring harness and electrical connectors are not damaged when removing the exhaust manifold (2).

Note:
The exhaust manifold gasket (1) and sealing ring (3) are single use parts. They must be discarded after removal.

11. Remove the exhaust manifold (2).

Discard the exhaust manifold gasket (1) and sealing ring (3).

Installation Procedure

1. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection 62. Exhaust Manifold Cleaning and Inspection.





2. Install NEW exhaust manifold gasket (1) and NEW sealing ring (3) to the exhaust manifold (2).

Caution:
Refer to Exhaust System Inspection Caution Exhaust System Inspection Caution.

3. Install the exhaust manifold assembly to engine.





4. Install the NEW exhaust manifold to cylinder head retaining bolts (1).

Caution:
Refer to Fastener Caution Fastener Caution.

5. Tighten the exhaust manifold to cylinder head retaining bolts (2) working from the centre to the outside to 20 Nm (15 lb ft).

Note:
Make sure the sealing ring is seated correctly.

6. Lift the right catalytic converter (4) up and forward to connect to the exhaust manifold (3).

7. Clean the threads of the exhaust manifold to catalytic converter retaining studs with a suitable cleaning solvent.

8. Install the NEW right catalytic converter to exhaust manifold retaining nuts (1) and tighten to 45 Nm (33 lb ft)

9. Install the right side exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side.

10. Install the right side spark plugs to the cylinder head. Refer to Spark Plug Replacement Service and Repair.

11. Install the right side spark plug leads. Refer to Spark Plug Wire Inspection Testing and Inspection.

12. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement Oil Level Indicator Tube Replacement.

13. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).