Exhaust Manifold: Service and Repair

Exhaust Manifold Removal and Installation

WARNING: To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system has cooled off.

Removal
1. Disconnect negative cable at battery.
2. Remove air cleaner upper case and intake air hose.





3. Detach couplers from their bracket and disconnect oxygen sensor lead wires at couplers.
4. Remove oil level gauge guide (3).
5. Disconnect EGR pipe from right (No. 2) bank exhaust manifold.





6. Remove exhaust manifold covers (2) from exhaust manifolds (1).

NOTE: Detach EVAP canister from its bracket if necessary.

7. Hoist vehicle.
8. For 4WD vehicle, before disconnecting front propeller shaft, put match mark (1) on joint flange and propeller shaft to facilitate their installation as shown in figure.





9. For 4WD vehicle, disconnect propeller shaft from front differential.





10. Remove exhaust No.1 pipe (2).





11. Detach exhaust manifold stiffener (1) from transmission case (3).
12. Remove exhaust manifolds and their gaskets from cylinder heads.

Installation
1. Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust No.1 pipe.





2. Install exhaust manifolds.
^ Always install new bolts with pre-coated adhesive to the locations with * mark,
^ Tighten manifold nuts to specified torque.
3. Attach exhaust manifold stiffener to transmission.





4. Install exhaust No.1 pipe (1) and stiffener (3). Tighten exhaust No.1 pipe bolts and nuts to specified torque.





5. Reverse removal procedure to install front propeller shaft, if removed. When installing propeller shaft, align match mark (1). Use the following specification to torque universal joint flange.
6. Connect EGR pipe to left (No. 1) bank exhaust manifold (1).
7. Install exhaust manifold covers (2).





8. Install oil level gauge guide (3) using new O-ring.





9. Connect oxygen sensor lead wire couplers. Be sure to clamp its lead wires.
10. Connect negative cable to battery. Upon completion of installation, start engine and check that no exhaust gas leakage exists.