For 1990-2009 cars

## Exhaust Manifold Replacement Left

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the 3-way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
3. Disconnect the secondary lock on the electrical connector.
4. Disconnect the wiring harness connector (1) from the oxygen sensor electrical connector.
5. Remove the oxygen sensor connector from the spark plug wire harness bracket.
6. Remove the oxygen sensor from the exhaust manifold.
7. Disconnect the numbers 1, 3 and 5 spark plug wires from the spark plugs.
8. Remove numbers 3 and 5 spark plugs from the cylinder head.
9. Remove the two rear exhaust manifold studs and nut from the exhaust manifold.
10. Lower the vehicle.
11. Disconnect the EGR valve electrical connector.
12. Remove the Exhaust Gas Recirculation (EGR) valve adapter nuts (5).
13. Remove the EGR valve adapter bolt (4) from the exhaust manifold (2).
14. Remove the EGR valve adapter (3) from the cylinder head studs (6) and exhaust manifold (2).
15. Remove the number 1 spark plug from the cylinder head.
16. Remove the exhaust manifold heat shield nuts.
17. Remove the exhaust manifold heat shields from the exhaust manifold.
18. Remove the two front exhaust manifold studs and nut from the exhaust manifold.
19. Remove the left exhaust manifold and gasket from the cylinder head.
20. Remove the heat shield studs from the exhaust manifold, if necessary.

### Installation Procedure

1. Install the heat shield studs to the exhaust manifold, if necessary.
2. Install the left exhaust manifold gasket and manifold to the cylinder head studs.

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.

3. Install the two front exhaust manifold studs and nut to the exhaust manifold.

Tighten

• | Tighten the two front exhaust manifold studs to 15 N·m (11 lb ft).

• | Tighten the exhaust manifold nut to 18 N·m (13 lb ft).

4. Install the exhaust manifold heat shields to the exhaust manifold.
5. Install the exhaust manifold heat shield nuts.

Tighten
Tighten the exhaust manifold heat shield nuts to 10 N·m (89 lb in).

6. Install the number 1 spark plug to the cylinder head.

Tighten
Tighten the number 1 spark plug to 27 N·m (20 lb ft).

7. Install the EGR valve adapter (3) to the cylinder head studs (6) and exhaust manifold (2).
8. Install the EGR valve adapter bolt (4) to the exhaust manifold (2).
9. Install the EGR valve adapter nuts (5).

Tighten

• | Tighten the EGR valve adapter nuts (5) to 50 N·m (37 lb ft).

• | Tighten the EGR valve adapter bolt (4) to 25 N·m (18 lb ft).

10. Connect the EGR valve electrical connector.
11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
12. Install the two rear exhaust manifold studs and nut to the exhaust manifold.

Tighten

• | Tighten the two rear exhaust manifold studs to 15 N·m (11 lb ft).

• | Tighten the exhaust manifold nut to 18 N·m (13 lb ft).

13. Install numbers 3 and 5 spark plugs to the cylinder head.

Tighten
Tighten numbers 3 and 5 spark plugs to 27 N·m (20 lb ft).

14. Connect the numbers 1, 3 and 5 spark plug wires to the spark plugs.
15. Install the oxygen sensor to the exhaust manifold.

Tighten
Tighten the oxygen sensor to 42 N·m (31 lb ft).

16. Install the oxygen sensor connector (1) to the spark plug wire harness bracket.
17. Connect the oxygen sensor electrical connector.
18. Connect the secondary lock on the electrical connector.
19. Install the 3-way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
20. Lower the vehicle.

## Exhaust Manifold Replacement Right

### Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the 3-way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
3. Disconnect the secondary lock on the electrical connector.
4. Disconnect the oxygen sensor electrical connector (3).
5. Remove the oxygen sensor connector rosebud from the engine left bracket.
6. Remove the oxygen sensor from the exhaust manifold.
7. Disconnect the numbers 4 and 6 spark plug wires from the spark plugs.
8. Remove the number 6 spark plug from the cylinder head.
9. Remove the two rear exhaust manifold studs and nut from the exhaust manifold.
10. Lower the vehicle.
11. Disconnect the number 2 spark plug wire from the spark plug.
12. Remove the numbers 2 and 4 spark plugs from the cylinder head.
13. Remove the exhaust manifold heat shield nuts.
14. Remove the exhaust manifold heat shields from the exhaust manifold.
15. Remove the two front exhaust manifold studs and nut from the exhaust manifold.
16. Remove the right exhaust manifold and gasket from the cylinder head.
17. Remove the heat shield studs from the exhaust manifold, if necessary.

### Installation Procedure

1. Install the heat shield studs to the exhaust manifold, if necessary.
2. Install the right exhaust manifold gasket and manifold to the cylinder head studs.

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.

3. Install the two front exhaust manifold studs and nut to the exhaust manifold.

Tighten

• | Tighten the two front exhaust manifold studs to 15 N·m (11 lb ft).

• | Tighten the exhaust manifold nut to 18 N·m (13 lb ft).

4. Install the exhaust manifold heat shields to the exhaust manifold.
5. Install the exhaust manifold heat shield nuts.

Tighten
Tighten the exhaust manifold heat shield nuts to 10 N·m (89 lb in).

6. Install the numbers 2 and 4 spark plugs to the cylinder head.

Tighten
Tighten the numbers 2 and 4 spark plugs to 27 N·m (20 lb ft).

7. Connect the number 2 spark plug wire to the spark plug.
8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Install the two rear exhaust manifold studs and nut to the exhaust manifold.

Tighten

• | Tighten the two rear exhaust manifold studs to 15 N·m (11 lb ft).

• | Tighten the exhaust manifold nut to 18 N·m (13 lb ft).

10. Install the number 6 spark plug to the cylinder head.

Tighten
Tighten the number 6 spark plug to 27 N·m (20 lb ft).

11. Connect the numbers 4 and 6 spark plug wires to the spark plugs.
12. Install the oxygen sensor to the exhaust manifold.

Tighten
Tighten the oxygen sensor to 42 N·m (31 lb ft).

13. Connect the oxygen sensor connector rosebud to the engine left bracket.
14. Connect the oxygen sensor electrical connector (3).
15. Connect the secondary lock on the electrical connector.
16. Install the 3-way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
17. Lower the vehicle.