Exhaust Manifold: Service and Repair

Exhaust Manifold

Removal
1. Raise and support the vehicle.





2. Detach the catalyst bracket and disconnect the plugs for the heated oxygen sensor (H02S).
3. Lower the vehicle.





4. Detach the heat shield.





5. Remove the air cleaner housing.
1. Pull out the plug of the mass air flow (MAF) sensor.
2. Detach the positive crankcase ventilation (PCV) hose.
3. Detach the intake hose.
^ Remove the air cleaner housing from the rubber bushings.
6. Remove and discard the exhaust gas recirculation (EGR) tube.





7. Detach the exhaust manifold from the catalyst.





8. Detach the exhaust manifold from the cylinder head.

Installation





1. Attach the exhaust manifold to the cylinder head using the alignment spacers with the two outside bolts and a new manifold gasket.





2. CAUTION: Always follow the correct installation sequence for the catalytic converter in order to prevent damage.

CAUTION: Do not allow debris to fall into the exhaust manifold.

NOTE: Examine the threads in the exhaust catalyst cone and EGR. Clean as required.

Loosen the bracket for the catalytic converter so that it can move freely.





3. NOTE: Use a new gasket.

NOTE: Do not fully tighten the nuts/bolts at this stage.

Position the catalytic converter on the exhaust manifold using new hardware.
4. Raise and support the vehicle.





5. Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.





6. Tighten the catalytic converter to the exhaust manifold.





7. NOTE: Always use a new catalyst to EGR valve pipe assembly.

NOTE: Loosely assemble the pipe to both the EGR valve and the exhaust catalyst before tightening the unions.
Attach the catalytic converter.
1. Tighten the bolts on the catalytic converter bracket.
2. Install a new EGR-pipe.
3. Attach the heat shield.





8. Attach the bracket for the catalytic converter.
^ Tighten the bolts.
^ Remove the temporary bolt from the rear catalytic converter bracket.
9. Lower the vehicle.





10. Attach the air filter housing.
^ Press the air filter housing into the rubber bushings.
1. Push on the mass air flow (MAF) sensor multiplug.
2. Attach the PCV hose.
3. Attach the intake hose.