For 1990-2009 cars

### Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

### Exhaust Manifold Removal with PUP Catalytic Converter

1. Remove the four bolts and separate the lower exhaust pipe from the exhaust manifold.
2. Remove the exhaust manifold stiffener bracket from the exhaust manifold.
3. Lower the vehicle.
4. Disconnect the oxygen sensor electric connector.
5. Remove the three bolts and the exhaust manifold heat shield (1) from the exhaust manifold.
6. If vehicle is equipped with A/C, remove the low side A/C line bracket and carefully reposition the A/C lines.
7. Remove the eight bolts and the one nut from the exhaust manifold.
8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket (1) from the cylinder head.

### Exhaust Manifold Removal without PUP Catalytic Converter

1. Remove the two bolts and the front pipe/catalytic converter assembly (2) from the exhaust manifold (1).
2. Lower the vehicle.
3. Disconnect the oxygen sensor electric connector.
4. Remove the four bolts and the exhaust manifold heat shield (5) from the exhaust manifold.
5. If vehicle is equipped with A/C, remove the low side A/C line bracket and carefully reposition the A/C lines.
6. Remove the five bolts and the three nuts from the exhaust manifold.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket (1) from the cylinder head.

### Exhaust Manifold Installation with PUP Catalytic Converter

1. Install the new exhaust manifold gasket (2) to the cylinder head.

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.

2. Install the exhaust manifold (3). Secure the exhaust manifold with the eight bolts and one nut.

Tighten
Tighten the exhaust manifold bolts and nut to 32 N·m (24 lb ft).

3. Install the exhaust manifold heat shield (1) to the exhaust manifold. Secure the exhaust manifold heat shield with the three bolts.

Tighten
Tighten the heat shield bolts to 15 N·m (11 lb ft).

4. Install the low side A/C line bracket. Secure the low side A/C line bracket with one bolt.

Tighten
Tighten the low side A/C line bracket bolt to 15 N·m (11 lb ft).

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Install the exhaust manifold stiffener bracket. Secure the bracket with the two bolts.

Tighten
Tighten the exhaust manifold stiffener bracket bolts to 50 N·m (37 lb ft).

7. Install the front pipe assembly to the exhaust manifold with the new seal. Secure the assembly with the four bolts.

Tighten
Tighten the exhaust manifold-to-front pipe assembly bolts to 50 N·m (37 lb ft).

8. Lower the vehicle.
9. Connect the oxygen sensor electrical connector.
10. Connect the negative battery cable.
11. Check the exhaust system for exhaust gas leakage.

### Exhaust Manifold Installation without PUP Catalytic Converter

1. Install the new exhaust manifold gasket (1) to the cylinder head.

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.

2. Install the exhaust manifold (2). Secure the exhaust manifold with the five bolts and the three nuts.

Tighten
Tighten the exhaust manifold bolts and nuts to 23 N·m (17 lb ft).

3. Install the exhaust manifold heat shield (6 ) to the exhaust manifold. Secure the exhaust manifold heat shield with the four bolts.

Tighten
Tighten the heat shield bolts to 15 N·m (11 lb ft).

4. Install the low side A/C line bracket. Secure the low side A/C line bracket with one bolt.

Tighten
Tighten the low side A/C line bracket bolt to 15 N·m (11 lb ft).

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Install the front pipe/catalytic converter assembly (2) to the exhaust manifold with the new seal. Secure the assembly with the two bolts.

Tighten
Tighten the exhaust manifold-to-front pipe/catalytic converter assembly bolts to 43 N·m (32 lb ft).

7. Lower the vehicle.
8. Connect the oxygen sensor electrical connector.
9. Connect the negative battery cable.
10. Check the exhaust system for exhaust gas leakage.