For 1990-2009 cars

### Removal Procedure

Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

1. Ignition OFF.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the intake manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.
4. Remove the left pre-catalytic convertor heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
5. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side.
6. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal.
7. Remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side.
8. Remove the battery positive cable retaining nut (1) from the starter motor solenoid.
9. Remove the battery positive cable (2) from the starter motor.

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

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

Discard the bolts.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Important: 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.

Important: Make sure that the surrounding wiring harness and electrical connectors are not damaged when removing the exhaust manifold (2).

Important: 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) from the engine assembly.
14. Separate the exhaust manifold (2) from the exhaust manifold gasket (1) and sealing ring (3).
15. Discard the exhaust manifold gasket (1) and sealing ring (3).

### Installation Procedure

1. Inspect the exhaust manifold before installation. Refer to Exhaust Manifold Cleaning and Inspection - Left Side.

Important: Make sure the sealing ring is seated correctly.

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

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Important: A suitable support must be used to support the exhaust manifold while the vehicle is being lowered.

4. Install the exhaust manifold assembly (2) to the engine.

Important: Do not fully tighten the exhaust manifold to cylinder head retaining bolts (1) at this stage.

5. Install NEW exhaust manifold to cylinder head retaining bolts (1).

Caution: Refer to Fastener Caution in the Preface section.

6. Tighten the exhaust manifold to cylinder head retaining bolts (1) working from the centre to the outside.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

7. Lower the vehicle.

Important: Do not fully tighten the exhaust manifold to cylinder head retaining bolts (1) at this stage.

8. Install NEW exhaust manifold to cylinder head retaining bolts (1).

Caution: Refer to Fastener Caution in the Preface section.

9. Tighten the exhaust manifold to cylinder head retaining bolts (1) working from the centre to the outside.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

10. Install the battery positive cable (2) to the starter motor.
11. Install the battery positive cable retaining nut (1) to the starter motor solenoid.

Tighten
Tighten the nut to 10 N·m (89 lb in).

12. Install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side.
13. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side.
14. Install the left pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
15. Install the intake manifold sight shield. Refer to Intake Manifold Sight Shield Replacement.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.