For 1990-2009 cars

## Exhaust Manifold Replacement In Vehicle - L61

### Removal Procedure

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

1. Raise the vehicle on a hoist.
2. Remove the exhaust manifold pipe-to-exhaust manifold nuts. Automatic shown, manual similar.

Notice: Avoid excessive movement of the pipe.

3. Pull down on the exhaust manifold pipe just enough to free from the manifold studs and secure to the frame.
4. Lower the vehicle.
5. Remove the exhaust manifold heat shield.
6. Disconnect the exhaust manifold heated oxygen sensor electrical connection.
7. Remove the heated oxygen sensor from the manifold.
8. Remove the exhaust manifold nuts.
9. Remove the exhaust manifold and discard the gasket.

### Installation Procedure

1. Install the new exhaust manifold gasket on the cylinder head.
2. Install the exhaust manifold.
3. Install the exhaust manifold nuts.

Tighten
Tighten the exhaust manifold-to-cylinder head nuts to 18 N·m (13 lb ft).

4. Install the heated oxygen sensor.

Tighten
Tighten the oxygen sensor-to-exhaust manifold pipe to 45 N·m (33 lb ft).

5. Connect the exhaust manifold heated oxygen sensor electrical connection.
6. Install the exhaust manifold heat shield.

Tighten
Tighten the exhaust manifold heat shield bolts to 25 N·m (18 lb ft).

7. Install the new exhaust manifold flange gasket onto the exhaust manifold flange studs.
8. Raise the vehicle on a hoist.
9. Position the exhaust manifold pipe flange onto the exhaust manifold studs.

Tighten
Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (22 lb ft).

10. Lower the vehicle.
11. Start the vehicle and inspect for leaks.

## Exhaust Manifold Replacement Rear - L81

#### Tools Required

J 39194-C Oxygen Sensor Wrench

### Removal Procedure

1. Disconnect the exhaust manifold heated oxygen sensor electrical connection.
2. Remove the exhaust manifold heated oxygen sensor using the J 39194-C .
3. Remove the EGR pipe.

Important: Do not apply grease or silicon products to the heated oxygen sensor (H02S-2). Do not alter the wiring in any way. The wires carry air reference to the sensor.

4. Disconnect the rear exhaust manifold pipe heated oxygen sensor electrical connection.
5. Remove the rear exhaust manifold pipe heat shield.
6. Remove the rear exhaust manifold pipe heated oxygen sensor.

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

7. Raise the vehicle on a hoist.
8. Remove the rear exhaust manifold pipe to front exhaust manifold pipe attachment bolts.
9. Remove the rear exhaust manifold pipe to resonator bolts.
10. Remove the rear exhaust manifold pipe assembly from the vehicle.
11. Remove the exhaust manifold nuts.
12. Remove the exhaust manifold and gasket.

### Installation Procedure

1. Install the exhaust manifold and the new gasket.
2. Install the exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nut to 20 N·m (15 lb ft).

3. Install the rear exhaust manifold pipe assembly and gaskets.

Important: Do not tighten the fasteners.

4. Install the exhaust manifold to rear exhaust manifold pipe nuts.
5. Install the front exhaust manifold pipe to rear exhaust manifold pipe attachment bolts.

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

6. Install the rear exhaust manifold pipe to resonator bolts.

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

7. Tighten the rear exhaust manifold pipe to exhaust manifold nuts.

Tighten
Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (25 lb ft).

8. Lower the vehicle.
9. Install the EGR pipe to the exhaust manifold and EGR flange.

Tighten
Tighten the EGR pipe bolts to 25 N·m (18 lb ft).

Notice: Refer to Heated Oxygen Sensor Damage Notice in the Preface section.

10. Install the heated oxygen sensor using the J 39194-C .

Tighten
Tighten the oxygen sensors (exhaust manifold) to 50 N·m (37 lb ft).

11. Connect the rear exhaust manifold pipe heated oxygen sensor electrical connections.
12. Install the exhaust manifold pipe heat shield.

Tighten
Tighten the exhaust manifold pipe heat shield bolts to 8 N·m (71 lb in).

13. Start the vehicle and inspect for exhaust leaks.