Exhaust Manifold: Service and Repair

NOTE: Step numbers below refer to numbers used in the illustrations.

REMOVAL
1. Disconnect the oxygen sensor's cables and undo the cable clamp and the clip.
2. Lift up the car.
3. Unscrew the nuts between the exhaust manifold and the front exhaust pipe and lower the pipe.
- Lower the car.
4. Relieve the tension on the belt tensioner using an extension to a ratchet and insert a 6mm drill into the hole, see illustration.
- Be very careful not to buckle the belt tensioner when it is in its end position.
- Remove the belt from the pulley on the steering servo pump.
5. Remove the steering servo pump's bracket with the pump and turn it to one side.





6. Undo the nuts on the exhaust manifold.
- The middle part must be removed before the outer part.
- Note that there are sleeves only on the outer stud screws.
7. Remove the exhaust manifold with its seal.





INSTALLATION
1. Clean the surfaces and install the exhaust manifold with a new seal.
- The outer part must be fitted before the inner part.
- Check that the connecting surfaces to the front exhaust pipe are level in order to avoid leakage.
- Note that there are sleeves only on the outer stud screws, then tighten to: 25 Nm (18.5 ft. lbs.).





2. Install the steering servo pump's console with pump and install the belt.
3. Release the tension on the belt tensioner with an extension to a ratchet, then remove the drill.
4. Lift up the car.
- Push up the front exhaust pipe and pull the joint together, then tighten to:40 Nm (30 ft. lbs.).
5. Lower the car.
6. Reconnect the oxygen sensor's cables and install the cable clamp and the clip.