Exhaust Manifold: Service and Repair

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.





2. Remove the oxygen sensor lead.
3. Remove the drive belt. See Engine.
4. Remove the generator rear brace.
5. Remove the generator. See Starting and Charging.
6. Raise and support the vehicle.
7. Remove the exhaust pipe to the exhaust manifold.
8. Lower the vehicle.





9. Remove the oil fill tube. See engine.
10. Remove the heater outlet hose assembly nut from the exhaust manifold.





11. Remove the exhaust manifold nuts.
12. Remove the exhaust manifold and the gasket.
13. Clean the mating surfaces at the cylinder head and the exhaust manifold.
14. Inspect the manifold for cracks, broken flanges and gasket surface damage.
15. Check the alignment of the exhaust manifold mating surfaces. Use a straight edge and a feeler gauge. If the flanges or the mating surfaces do not align, the manifold is warped and should be replaced.

INSTALLATION PROCEDURE





1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold nuts. Tighten the nuts to 13 Nm (115 inch lbs.).
4. Install the heater outlet hose assembly nut. Tighten the nut to 25 Nm (18 ft. lbs.).
5. Install the oil fill tube. See Engine.
6. Raise the vehicle.
7. Install the exhaust pipe to the manifold.
8. Lower the vehicle.
9. Install the generator. See Starting and Charging.
10. Install the generator rear brace.
11. Install the drive belt. See Engine.
12. Install the oxygen sensor lead.
13. Connect the negative battery cable.