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.

## Exhaust Manifold Replacement Front - L81

#### Tools Required

• | J 39194-C Oxygen Sensor Wrench

• | SA9105E Engine Support Fixture (3 Bar)

### Removal Procedure

1. Disconnect the exhaust manifold heated oxygen sensor (HO2S) electrical connection.
2. Remove the exhaust manifold HO2S using the J 39194-C .
3. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the upper radiator hose from the coolant extension housing.

Important: The powertrain must be lifted up in order to remove the coolant extension housing.

5. Install the SA9105E and support the powertrain.
6. Remove the front transaxle mount through bolt.
7. Raise the powertrain with the engine support fixture to provide clearance to pull the extension housing above the coolant module.
8. Remove the oil level indicator tube and coolant extension tube bolt.
9. Remove the oil level indicator by pulling upwards.
10. Twist the coolant extension housing to remove.
11. Remove the power steering pipe bracket bolt.
12. Remove the upper exhaust manifold nuts.
13. Disconnect the front exhaust manifold pipe HO2S electrical connection.

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

14. Raise the vehicle.
15. Remove the front exhaust manifold pipe to exhaust manifold nuts.
16. Remove the front exhaust manifold pipe to rear exhaust manifold pipe bolts.
17. Remove the front exhaust manifold pipe assembly.
18. Remove the oil filter housing assembly.
19. Remove the lower exhaust manifold nuts.
20. Remove the exhaust manifold and gasket.

### Installation Procedure

1. Install the exhaust manifold and new gasket.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the lower exhaust manifold nuts.

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

3. Install the oil filter housing to block.

Tighten
Tighten the oil filter cartridge housing-to-engine to 45 N·m (33 lb ft).

4. Install the oil filter cap and filter to housing.

Tighten
Tighten the oil filter cap to 15 N·m (11 lb ft).

5. Install the front exhaust manifold pipe assembly and gaskets.

Important: Do not tighten the fasteners.

6. Install the front exhaust manifold pipe to rear exhaust manifold pipe bolts.
7. Install the front 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. Tighten the front exhaust manifold pipe to rear exhaust manifold pipe bolts.

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

Notice: Always use a nickle-based anti-seize compound Saturn P/N 21485279 (or equivalent) on the threads of the heated oxygen sensor (H02S-2). If the H02S-2 is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicone products. Silicone products will damage the sensor.

9. Install the front exhaust manifold pipe HO2S.

Tighten
Tighten the oxygen sensors (lower exhaust pipe) to 45 N·m (33 lb ft).

10. Lower the vehicle.
11. Connect the front exhaust manifold pipe HO2S electrical connection.
12. Install the upper exhaust manifold nuts.

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

13. Install the power steering pipe bracket bolt.

Tighten
Tighten the power steering pipe bracket bolt to 8 N·m (71 lb in).

14. Install 2 new O-rings onto the coolant extension housing.
15. Lubricate the O-rings with coolant and install the extension housing.
16. Install the oil level indicator tube and coolant extension housing bolt.

Tighten
Tighten the coolant extension housing bolt to 20 N·m (15 lb ft).

17. Lower the powertrain and align the front transaxle mount and mounting bracket using the engine support fixture.
18. Install the front transaxle mount through bolt.

Tighten
Tighten the transaxle mount through bolt to 55 N·m (41 lb ft).

19. Remove the SA9105E , or equivalent.
20. Install the upper radiator hose.
21. Refill the coolant.
22. Install the exhaust manifold HO2S using the J 39194-C .

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

23. Connect the exhaust manifold HO2S electrical connection.
24. Start the vehicle and check for coolant and exhaust leaks.