Exhaust Manifold Replacement Left

1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
2. Disconnect the engine coolant temperature (ECT) gauge sensor electrical connector.



3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the left front tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
5. Remove the left fender wheelhouse extension (1).
6. Remove the catalytic converter assembly. Refer to Catalytic Converter Replacement in Engine Exhaust.



7. Remove the EGR valve inlet pipe from the exhaust manifold.



8. Remove the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
9. Remove the spark plug wire support bolts.
10. Remove the spark plug wire support with the spark plug wires.
11. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
12. Remove the AIR pipe from the exhaust manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 1 in Engine Controls.



13. Remove the exhaust manifold, gaskets and the spark plug wire shields from underneath the vehicle.
14. Clean all gasket surfaces. Refer to Exhaust Manifold Cleaning and Inspection .

Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place.

1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. Install the exhaust manifold. Refer to Exhaust Manifold Installation .



4. Install the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
5. Install the spark plug wires to the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
6. Install the AIR pipe to the exhaust manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 1 in Engine Controls.

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.

7. Install the spark plug wire support and bolts.

Tighten
Tighten the spark plug wire support bolts to 12 N·m (106 lb in).




8. Install the EGR valve inlet pipe to the exhaust manifold.

Tighten
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).

9. Install the catalytic converter assembly. Refer to Catalytic Converter Replacement in Engine Exhaust.



10. Install the fender wheelhouse extension (1).
11. Install the left front tire. Refer to Tire and Wheel Removal and Installation in Tire and Wheels.
12. Lower the vehicle.



13. Connect the ECT gauge sensor electrical connector.
14. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.

Exhaust Manifold Replacement Right

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the right front tire. Refer to Tire and Wheel Removal and Installation in Tire and Wheels.
3. Remove the right fender wheelhouse extension (1).



4. Disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
5. Remove the bolts and the spark plug wire support.
6. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
7. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
8. Remove the catalytic converter assembly. Refer to Catalytic Converter Replacement in Engine Exhaust.
9. Remove the AIR pipe from the exhaust manifold, if equipped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 2 in Engine Controls.



10. Remove the exhaust manifold bolts through the wheelhouse.
11. Remove the exhaust manifold with the exhaust manifold gaskets and the spark plug wire shields from the engine.
12. Clean all gasket surfaces. Refer to Exhaust Manifold Cleaning and Inspection .

Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place.

1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. Install the exhaust manifold. Refer to Exhaust Manifold Installation .
4. Install the AIR pipe to the exhaust manifold, if equipped. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 2 in Engine Controls.
5. Install the catalytic converter assembly. Refer to Catalytic Converter Replacement in Engine Exhaust.
6. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.



7. Install the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
8. Install the spark plug wire support and bolts.

Tighten
Tighten the spark plug wire support bolts to 12 N·m (106 lb in).

9. Install the spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



10. Install the fender wheelhouse extension (1).
11. Install the front tire. Refer to Tire and Wheel Removal and Installation in Tire and Wheels.
12. Lower the vehicle.