Exhaust Manifold Replacement - Front

REMOVAL





1. Disconnect exhaust manifold oxygen sensor electrical connection.
2. Remove exhaust manifold oxygen sensor using J-39194-C, oxygen sensor socket.





3. Drain coolant.





4. Remove upper radiator hose from coolant extension housing.





5. Install engine support fixture and adapters SA915OE and J-43405 (or equivalent) and support powertrain.

IMPORTANT: The powertrain must be lifted up in order to remove the coolant extension housing.





6. Remove front transaxle mount through bolt.





7. Raise powertrain with engine support fixture to provide clearance to pull extension housing above coolant module.
8. Remove oil level indicator tube and coolant extension tube bolt.
9. Remove oil level indicator tube by pulling upwards.





10. Twist coolant extension housing to remove.





11. Remove power steering pipe bracket bolt.
12. Remove upper exhaust manifold nuts.





13. Disconnect front exhaust manifold pipe oxygen sensor electrical connection.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST.

14. Raise vehicle.
15. Remove front exhaust manifold pipe to exhaust manifold nuts.





16. Remove front exhaust manifold pipe to rear exhaust manifold pipe bolts.
17. Remove front exhaust manifold pipe assembly.





18. Remove oil filter housing assembly.





19. Remove lower exhaust manifold nuts.
20. Remove exhaust manifold and gasket.

INSTALLATION





1. Install exhaust manifold and new gasket
2. Install lower exhaust manifold nuts.
^ Torque: 20 Nm (15 ft. lbs.)





3. Install oil filter housing to block.
^ Torque: 45 Nm (33 ft. lbs.)
4. Install oil filter cap and filter to housing.
^ Torque: 25 Nm (18 ft. lbs.)





5. Install front exhaust manifold pipe assembly and gaskets.

NOTICE: Do not tighten fasteners.

6. Install front exhaust manifold pipe to rear exhaust manifold pipe bolts.





7. Install front exhaust manifold pipe to exhaust manifold nuts.
^ Torque: 30 Nm (25 ft. lbs.)
8. Tighten front exhaust manifold pipe to rear exhaust manifold pipe bolts.
^ Torque: 20 Nm (15 ft. lbs.)

NOTICE: Always use a nickel-based anti-seized compound (Saturn P/N 21485279 or equivalent) on the threads of the oxygen sensor. If the oxygen sensor is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicon product; silicon products will cause damage to oxygen sensor.





9. Install front exhaust manifold pipe oxygen sensor.
^ Torque: 45 Nm (73 ft. lbs.)
10. Lower vehicle.
11. Connect front exhaust manifold pipe oxygen sensor electrical connection.





12. Install upper exhaust manifold nuts.
^ Torque: 20 Nm (15 ft. lbs.)
13. Install power steering pipe bracket bolt.
^ Torque: 8 Nm (71 inch lbs.)





14. Install two new O-rings onto coolant extension housing.
15. Lubricate O-ring with coolant and install extension housing.
16. Install oil level indicator tube and coolant extension housing bolt.
^ Torque: 20 Nm (15 ft. lbs.)





17. Lower powertrain and align front transaxle mount and mounting bracket using engine support fixture.





18. Install front transaxle mount through bolt.
^ Torque: 55 Nm (41 ft. lbs.)





19. Remove engine support fixture and adapters SA9lSOE and J43405 (or equivalent).





20. Install upper radiator hose.





21. Refill coolant.





22. Install exhaust manifold oxygen sensor using J-39194C, oxygen sensor socket.
^ Torque: 50 Nm (37 ft. lbs.)
23. Connect exhaust manifold oxygen sensor electrical connection.
24. Start vehicle and check for coolant and exhaust leaks.