Exhaust Manifold Replacement Right

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the exhaust pipe from the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
3. Lower the vehicle.
4. Remove the bolt for the oil level indicator tube.
5. Disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



6. Remove the nuts holding the secondary air injection (AIR) pipe assembly, if equipped to the exhaust manifold.
7. Remove the AIR pipe and gasket from the exhaust manifold.
8. Remove the exhaust manifold. Refer to Exhaust Manifold Removal .
9. Clean all gasket surfaces. Refer to Exhaust Manifold Cleaning and Inspection .

Important: To assist in installing the exhaust manifold to the engine, the tabs at the bolt holes on a NEW exhaust manifold gasket will hold the bolts and the gaskets in place.

1. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold.
2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. Install the exhaust manifold. Refer to Exhaust Manifold Installation .
4. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



5. Install the AIR pipe and a NEW gasket to the exhaust manifold.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the AIR pipe nuts.

Tighten
Tighten the AIR pipe nuts to 25 N·m (18 lb ft).

7. Raise the vehicle.
8. Connect the exhaust pipe to the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
9. Lower the vehicle.
10. Install the bolt for the oil level indicator tube.

Tighten
Tighten the oil level indicator tube bolt to 12 N·m (106 lb in).

Exhaust Manifold Replacement Left

1. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
2. Remove the intermediate steering shaft. Refer to Lower Intermediate Steering Shaft Replacement in Steering Wheel and Column - Standard.



3. Disconnect the engine coolant temperature (ECT) sensor electrical connector.



4. Disconnect the exhaust gas recirculation (EGR) valve inlet pipe from the exhaust manifold.



5. Remove the radiator inlet hose support bracket and nut.



6. Remove the nuts holding the secondary air injection (AIR) pipe to the exhaust manifold, if equipped.
7. Remove the AIR pipe and gasket from the exhaust manifold.
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle
9. Disconnect the exhaust pipe from the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
10. Lower the vehicle to the proper height.
11. Remove the front tire to gain access to the rear exhaust manifold bolts. Refer to Tire and Wheel Removal and Installation in Tire and Wheels.



12. Remove the fender wheelhouse extension.
13. Working through the wheel house opening disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



14. Remove the exhaust manifold bolts and the stud.
15. Lower the vehicle.
16. From under the hood remove the exhaust manifold and the spark plug wire shields from the engine.
17. Clean all gasket surfaces. Refer to Exhaust Manifold Cleaning and Inspection .

Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and bolts in place.

1. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold.

The stud installs in the front hole.

2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. From under the hood position the exhaust manifold by the engine.
4. Raise the vehicle to the proper height.
5. Working the wheelhouse opening install the exhaust manifold. Refer to Exhaust Manifold Installation .
6. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



7. Install the fender wheelhouse extension.
8. Install the front tire to. Refer to Tire and Wheel Removal and Installation in Tire and Wheels.
9. Raise the vehicle.
10. Connect the exhaust pipe to the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
11. Lower the vehicle.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

12. Connect the EGR valve inlet pipe to the exhaust manifold.

Tighten
Tighten the EGR valve inlet pipe nut to 30 N·m (22 lb ft).




13. Connect the ECT sensor electrical connector.



14. Install the AIR pipe and a NEW gasket to the exhaust manifold.
15. Install the AIR pipe nuts.

Tighten
Tighten the AIR pipe nuts to 25 N·m (18 lb ft).




16. Install the radiator inlet hose support bracket and nut.

Tighten
Tighten the radiator inlet hose support bracket nut to 36 N·m (27 lb ft).

17. Install the intermediate steering shaft. Refer to Lower Intermediate Steering Shaft Replacement in Steering Wheel and Column - Standard.
18. Install the air cleaner outlet duct to the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.