Exhaust Manifold: Service and Repair

REMOVAL

1. Disconnect cable from negative terminal of battery.

CAUTION: Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.

2. Remove engine under covers.
3. Disconnect front exhaust pipe.
4. Remove main oxygen sensor.
5. (CALIF. only) Remove sub-oxygen sensor.





6. Remove exhaust manifold and catalytic converter assembly.

a. Remove the six bolts and manifold upper heat insulator.





b. Remove the two bolts, two nuts and catalytic converter stay.





c. Remove the six nuts, the exhaust manifold and catalytic converter assembly.

INSTALLATION





1. Install exhaust manifold and catalytic converter assembly.

a. Install a new gasket, the exhaust manifold and catalytic converter assembly with the six new nuts. Uniformly tighten the nuts in several passes.
Torque: 49 Nm (36 ft lb)





b. Install the catalytic converter stay with the two bolts and two new nuts. Alternately tighten the bolts and nut.
Torque: 42 Nm (31 ft lb)





c. Install the manifold upper heat insulator with the six bolts.

2. (CALIF. only) Install sub-oxygen sensor.
3. Install main oxygen sensor.





4. Connect the front exhaust pipe.
a. Install the support hook on the front exhaust pipe to the support bracket.
b. Place two new gaskets on the front and rear of the front exhaust pipe.
c. Temporarily install the two bolts and new nuts holding the exhaust pipe to the center exhaust pipe.
d. Using a 14 mm deep socket wrench, install the three new nuts holding the exhaust pipe to the catalytic converter.
Torque: 62 Nm (46 ft lb)
e. Tighten the two bolts and nuts holding the exhaust pipe to the center exhaust pipe.
Torque: 43 Nm (32 ft lb)
f. Install the clamp with the bolt.
5. Install engine under covers.
6. Start engine and check for leaks.
7. Perform road test and check for abnormal noise.