For 1990-2009 cars

## Exhaust Manifold Pipe Replacement Automatic Transmission - L61

#### Tools Required

J 43628 Frame Alignment Fixture

### Removal Procedure

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

1. Raise the vehicle on a hoist.

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.

2. Remove the heated oxygen sensor from the heat shield.
3. Disconnect the heated oxygen sensor electrical connector.
4. Remove the heated oxygen sensor.
5. Remove the exhaust manifold pipe to exhaust manifold fasteners.
6. Remove the suspension support assemblies and discard the bolts.
7. Loosen the remaining frame attachment fasteners to allow clearance for the exhaust manifold pipe flange to pass by the frame.
8. Remove the exhaust manifold pipe to exhaust/resonator fasteners.
9. Remove the exhaust manifold pipe.

### Installation Procedure

1. Position the gasket on the manifold pipe.
2. Position the manifold pipe into the vehicle.

Important: Do not tighten the fasteners.

3. Install the exhaust manifold pipe to exhaust manifold nuts.
4. Position the gasket between the manifold pipe and resonator.
5. Install the exhaust manifold pipe to resonator bolts and tighten.

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

6. Tighten the exhaust manifold pipe to exhaust manifold nuts.

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

7. Install the J 43628 , or equivalent, and raise the fame to the vehicle.
8. Remove the remaining frame bolts and replace with new bolts and tighten.

Tighten
Tighten the frame-to-body bolts to 100 N·m (74 lb ft) + 45° + 60°.

9. Install the new cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.
10. Install the suspension supports using new bolts and tighten.

Tighten
Tighten the suspension support-to-body bolts to 90 N·m (60 lb ft) + 45° + 60°.

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

11. Install the heated oxygen sensor.

Tighten
Tighten the HO2S-2 sensor-to-exhaust pipe to 45 N·m (33 lb ft).

12. Connect the heated oxygen sensor harness connector.
13. Connect the heated oxygen sensor harness to heat shield.

Tighten
Tighten the HO2S-2 harness clip-to-heat shield bolt to 4 N·m (35 lb in).

14. Lower the vehicle from the hoist.
15. Start the engine and check for exhaust leaks.

## Exhaust Manifold Pipe Replacement Manual Transmission - L61

### Removal Procedure

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

1. Raise the vehicle on a hoist.

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.

2. Remove the heated oxygen sensor electrical connector.
3. Remove the heated oxygen sensor from the heat shield.
4. Remove the heated oxygen sensor.
5. Remove the nuts that hold the exhaust manifold pipe to the exhaust manifold.
6. Remove the bolts that hold the exhaust manifold pipe to exhaust resonator.
7. Remove the exhaust manifold pipe from the vehicle.

### Installation Procedure

1. Position the gasket on the exhaust manifold pipe.
2. Position the exhaust manifold pipe into the vehicle.

Important: Do not tighten the fasteners.

3. Install the nuts that hold the exhaust manifold pipe to exhaust manifold.
4. Position the gasket between the exhaust manifold pipe and exhaust resonator.
5. Install the bolts that hold the exhaust manifold pipe to exhaust resonator.

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

6. Tighten the nuts that hold the manifold pipe to exhaust manifold.

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

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

7. Install the heated oxygen sensor.
8. Connect the heated oxygen sensor harness connector.
9. Connect the heated oxygen sensor harness to the heat shield.
10. Lower the vehicle from the hoist.
11. Start the engine and check for exhaust leaks.