Exhaust Manifold Replacement Left

Tools Required

J 34730-1A Fuel Pressure Gauge

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 the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.



3. Remove the left hand intermediate pipe flange nuts from the exhaust manifold studs.
4. Remove the heat oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement in Engine Controls.
5. Lower the vehicle.



6. Remove the fuel rail cover.
7. Relieve the fuel system pressure using J 34730-1A . Refer to Fuel Pressure Relief in Engine Controls.



8. Disconnect the generator and coolant temperature sensor electrical connectors.



9. Remove the accessory drive belt (5) from the generator pulley (6).



10. Remove the generator. Refer to Generator Replacement in Engine Electrical.



11. Remove the secondary air injection (AIR) hose from the AIR check valve.



12. Remove the AIR pipe, bolts, and gasket from the exhaust manifold and reposition.
13. Remove the AIR pipe retainer from the rear of the cylinder head and reposition.



14. Remove the spark plug wires from the coils and the spark plugs.
15. Remove the spark plugs from the cylinder head. Refer to Spark Plug Replacement in Engine Electrical.



16. Remove the exhaust manifold. Refer to Exhaust Manifold Removal .
17. Discard the gasket.

1. Install the exhaust manifold. Refer to Exhaust Manifold Installation .
2. Install the spark plugs to the cylinder head. Refer to Spark Plug Replacement in Engine Electrical.



3. Install the spark plug wires to the spark plugs and the coils.




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.

4. Install the AIR pipe, bolts, and gasket to the exhaust manifold.

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

5. Install the AIR pipe retainer to the rear of the cylinder head.

Tighten
Tighten the AIR pipe retainer bolt to 20 N·m (15 lb ft).




6. Install the AIR hose to the AIR check valve.

Tighten
Tighten the AIR hose to the AIR check valve to 20 N·m (15 lb ft).

7. Install the generator. Refer to Generator Replacement in Engine Electrical.



8. Install the accessory drive belt (5) to the generator pulley (6).



9. Connect the generator and coolant temperature sensor electrical connectors.



10. Install the fuel rail cover to the engine.



11. Raise the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.
12. Install the HO2S sensor. Refer to Heated Oxygen Sensor Replacement in Engine Exhaust.
13. Install the intermediate pipe flange-to-the exhaust manifold studs.
14. Install the intermediate pipe flange nuts.

Tighten
Tighten the intermediate pipe flange nuts to 20 N·m (15 lb ft).

15. Lower the vehicle.
16. Connect the negative battery cable.

Tighten
Tighten the negative battery bolt to 15 N·m (11 lb ft).

17. Program the Transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.

Exhaust Manifold Replacement Right

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 the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.



3. Remove the right hand intermediate exhaust pipe nuts from the exhaust manifold studs.
4. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement in Engine Controls.
5. Lower the vehicle.



6. Remove the following air injection pipe (AIR) components:

6.1.

The bolts

6.2.

The pipe

6.3.	The gasket




7. Remove the spark plug wires from the spark plugs and coils.
8. Remove the spark plugs.



9. Remove the oil level indicator from the oil level indicator tube.
10. Remove the oil level indicator tube bolt.
11. Remove the oil level indicator tube from the engine.



12. Remove the exhaust manifold. Refer to Exhaust Manifold Removal .
13. Discard the gasket.

1. Install the exhaust manifold. Refer to Exhaust Manifold Installation .



2. If the O-ring seal is damaged, install a new O-ring on to the oil level indicator tube.
3. Install the oil indicator tube to the engine.
4. Rotate the tube into the proper position.

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.

5. Install the oil level indicator tube bolt.

Tighten
Tighten the oil level indicator bolt to 16 N·m (12 lb ft).

6. Install the oil level indicator to the tube.



7. Install the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
8. Install the spark plug wires to the spark plugs and coils.



9. Install the following air injection pipe components:

9.1.	The gasket

9.2.

The pipe

9.3.

The bolts

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

10. Raise the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.
11. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls.



12. Install the intermediate pipe flange to the exhaust manifold studs.
13. Install the intermediate pipe flange nuts.

Tighten
Tighten the intermediate pipe flange nuts to 20 N·m (15 lb ft).

14. Lower the vehicle.
15. Connect the negative battery cable.

Tighten
Tighten the negative battery bolt to 15 N·m (11 lb ft).

16. Program the Transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.