Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement

Removal Procedure






Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

1. Raise vehicle squarely on a lift.






2. Loosen front exhaust pipe clamp at engine block bracket and slide clamp out of engagement with bracket.






3. Remove front exhaust pipe-to-exhaust manifold nuts, lower front exhaust pipe, remove gasket and discard.
4. Lower vehicle.
5. Remove the A/C compressor and the rear compressor bracket. Refer to Service and Repair.






6. Disconnect oxygen sensor 1 harness connector.
7. Remove exhaust manifold attachment nuts.
8. Remove the exhaust manifold and gasket. Discard the gasket.
9. Inspect the exhaust manifold to front exhaust pipe flange for warpage.

Front Exhaust Pipe-to-Manifold Flange Warpage:

Standard: 0.7 mm (0.028 in) max.

Service Limit: 0.7 mm (0.028 in) max.

Installation Procedure






1. Install new exhaust manifold gasket with smooth side toward the exhaust manifold.
2. Install the exhaust manifold and attachment nuts.






3. In sequence, torque the exhaust manifold attachment nuts. The center fasteners may lose torque when the outer fasteners are tightened. Therefore, re-torque all fasteners a second time.

Tighten
Tighten Exhaust Manifold-to-Head (L24) 22 Nm (16 lbs ft).

Tighten
Tighten Exhaust Manifold-to-Head (LL0) 17 Nm (13 lbs ft).






Important: Whenever the oxygen sensor 1 is removed, coat the threads with a nickel based anti-seize such as Saturn P/N 21485279 (or equivalent). If oxygen sensor 1 is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Do not use an anti-seize that contains silicone.

4. Connect oxygen sensor 1 harness connector. Push in until a click is heard and pull back to ensure a positive engagement.

Tighten
Tighten Sensor - Oxygen-to-Exhaust Manifold 45 Nm (33 lbs ft).

5. Install A/C compressor rear bracket and A/C compressor. Refer to "Engine Drive Belt and Accessories Drive" section of this manual for A/C compressor installation.

Tighten
Tighten Front/Rear Brackets-to-Head/Block 25 Nm (19 lbs ft).

Tighten
Tighten Compressor-to-Front Bracket 54 Nm (40 lbs ft).

Tighten
Tighten Compressor-to-Rear Bracket 25 Nm (19 lbs ft).

6. Raise vehicle squarely on a lift.





7. Install new exhaust pipe-to-manifold gasket on the studs.
8. Install and torque the exhaust pipe-to-manifold attachment nuts.

Tighten
Tighten Exhaust Pipe-to-Manifold 31 Nm (23 lbs ft).






9. Slide front exhaust pipe clamp over engine block bracket and tighten clamp.

Tighten
Tighten Exhaust Pipe Clamp-to-Support Bracket 60 Nm (44 lbs ft).

10. Lower vehicle and check for leaks.