Exhaust Manifold: Service and Repair

Exhaust Manifold LH

Removal

All vehicles
1 Disconnect the battery ground cable. For additional information, refer to Battery Disconnect and Connect Battery Disconnect and Connect
2
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.




3 Release the coolant expansion tank for access.
- Remove the retaining nut and bolt.
- Remove the clip.
- Position the coolant expansion tank aside.




4 Release and tie aside the power steering reservoir.




5 Remove the oil level indicator and tube.
- Remove the nut.
- Discard the O-ring seal.




6 Remove the LH exhaust manifold heat shield retaining bolts.
7
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise the vehicle.
8 Remove the air deflector. For additional information, refer to Air Deflector Service and Repair
9 Remove the LH catalytic converter. For additional information, refer to Catalytic Converter Service and Repair

Left-hand drive vehicles





10 Disconnect the steering column lower shaft from the steering gear.
- Remove the steering column flexible coupling securing bolts.





11 Disconnect the steering gear control valve actuator electrical connector.





12 Detach the steering gear.
- Remove the steering gear retaining bolts.





13 Using suitable tie strap(s), secure the steering gear.

All vehicles





14 Remove the splash shield retaining clips.
- Position the splash shield to one side.





15 Remove the LH exhaust manifold heat shield retaining bolts.
- Remove the LH exhaust manifold heat shield.

Vehicles with secondary air injection (AIR)





16 Detach the secondary air injection (AIR) control valve to exhaust manifold tube from the exhaust manifold.

All vehicles





17 Remove the exhaust manifold.
- Remove and discard the 8 bolts.
- Remove the 8 spacers.





18 Remove and discard the LH exhaust manifold gasket.
- Remove the bolt.

Installation

All vehicles




1 Install the LH exhaust manifold gasket.
- Clean the component mating faces.
- Tighten the bolt to 50 Nm.




2 Install the LH exhaust manifold.
- Clean the component mating faces.
- Install the spacers.
- Evenly and progressively, tighten the new bolts in the sequence shown, to 24 Nm.

Vehicles with secondary air injection (AIR)




3 Attach the AIR control valve to exhaust manifold tube to the exhaust manifold.
- Tighten to 35 Nm.

All vehicles




4 Install the LH exhaust manifold heat shield.
- Tighten the bolts to 8 Nm.

Left-hand drive vehicles




5 Install the steering gear.
- Tighten the bolts to 100 Nm.




6 Connect the lower steering column shaft to the steering gear.
- Tighten the bolts to 35 Nm.




7 Connect the steering gear control valve actuator electrical connector.

All vehicles




8 Install the splash shield.
- Install the 2 clips.
9 Install the LH catalytic converter. For additional information, refer to Catalytic Converter Service and Repair

10 Install the air deflector. For additional information, refer to Air Deflector Service and Repair

11 Lower the vehicle.





12 Install the LH exhaust manifold heat shield retaining bolts.
- Tighten the bolts to 8 Nm.





13 With assistance, install the oil level indicator and tube.
- Clean the components.
- Install a new O-ring seal.
- Lubricate the O-ring seal with clean engine oil.
- Tighten the nut to 6 Nm.





14 Install the power steering fluid reservoir.





15 Attach the coolant expansion tank.
- Reposition the coolant expansion tank.
- Tighten the nut and bolt to 10 Nm.
- Install the clip.

16 Connect the battery ground cable. For additional information, refer to Battery Disconnect and Connect Battery Disconnect and Connect