Exhaust Manifold Replacement - Left Side

Exhaust Manifold Replacement - Left Side (V8)

Removal Procedure

Warning: Refer to Exhaust Service Warning (Service Precautions).

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 (Service and Repair).
3. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair).
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
5. Remove the left side spark plug leads. Refer to Spark Plug Replacement (Service and Repair).
6. Remove the left side spark plugs from the cylinder head. Refer to Exhaust Manifold Heat Shield Replacement - Right Side (V8) (Exhaust Manifold Heat Shield Replacement - Right Side)Exhaust Manifold Heat Shield Replacement - Right Side (V6) (Exhaust Manifold Heat Shield Replacement - Right Side).
7. Remove the left side exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (V8) (Exhaust Manifold Heat Shield Replacement - Left Side)Exhaust Manifold Heat Shield Replacement - Left Side (V6) (Exhaust Manifold Heat Shield Replacement - Left Side).
8. Remove the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement (Service and Repair).





Note: The left catalytic converter to exhaust manifold retaining nuts (2) are single use parts. They must be discarded after removal.

9. Remove the left catalytic converter to exhaust manifold retaining nuts (2).
Discard the nuts.
10. Disconnect the left catalytic converter (3) from the exhaust manifold (4).
11. Loosen the exhaust manifold to cylinder head retaining bolts (1) working from the outside to the centre.

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

12. Remove the exhaust manifold to cylinder head retaining bolts (1).
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.

13. 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 (Overhaul).




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

Caution: Refer to Exhaust System Inspection Caution (Service Precautions).

3. Install the exhaust manifold assembly to the 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 (1) 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 left catalytic converter (3) up and forward to connect to the exhaust manifold (4).
7. Clean the threads of the exhaust manifold to catalytic converter retaining studs with a suitable cleaning solvent.
8. Install the NEW left catalytic converter to exhaust manifold retaining nuts (2) and tighten to 45 Nm (33 lb ft).
9. Install the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement (Service and Repair).
10. Remove the install the left side exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side (V8) (Exhaust Manifold Heat Shield Replacement - Left Side)Exhaust Manifold Heat Shield Replacement - Left Side (V6) (Exhaust Manifold Heat Shield Replacement - Left Side).
11. Install the left side spark plugs to the cylinder head. Refer to Spark Plug Replacement (Service and Repair).
12. Install the left side spark plug leads. Refer to Spark Plug Wire Inspection (Testing and Inspection).
13. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
14. Install the engine cover. Refer to Engine Cover Replacement (Service and Repair).
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).