Exhaust manifold – removal and installation
Warning: The engine must be completely cool before beginning this procedure.
Removal
1. Disconnect the cable from the negative terminal of the battery (see Engine electrical systems).
2. Block the rear wheels, set the parking brake, raise the front of the vehicle and support it securely on jackstands.
3. Unbolt the exhaust pipe from the exhaust manifold. Note: On. V8 models, you must soak the nuts for at least five minutes with penetrating oil, then replace the fasteners with new ones.
Right side exhaust manifold, V8 models
4. Remove the drivebelt (see Tune-up and routine maintenance).
5. Drain the engine coolant below the level of the heater hoses (see Tune-up and routine maintenance).
6. Remove the air inlet duct and air filter housing (see Fuel and exhaust systems – gasoline engines).
7. Remove the air conditioning compressor (see Cooling, heating and air conditioning systems).
8. Remove the air conditioning accumulator bracket fastener.
9. Disconnect the heater hoses from the engine (see Cooling, heating and air conditioning systems).
10. Remove the starter (see Engine electrical systems).
Either manifold, all models
11. Remove the exhaust manifold heat shields.
12. Remove the exhaust manifold mounting bolts and remove the manifold from the vehicle. Lower the exhaust manifold and remove it from under the vehicle.
Installation
13. Clean the mating surfaces to remove all traces of old gasket material, then inspect the manifold for distortion and cracks. Warpage can be checked with a precision straightedge held against the mating flange. If a feeler gauge thicker than 0.030-inch can be inserted between the straightedge and flange surface, take the manifold to an automotive machine shop for resurfacing.
14. Place the exhaust manifold in position with a new gasket and install the mounting bolts finger tight.
15. Starting in the middle and working out toward the ends, tighten the mounting bolts in several increments, to the torque listed in this Chapter’s Specifications. Tighten the heat shield bolts to the torque listed in this Chapter’s Specifications.
16. Install the remaining components in the reverse order of removal. If you’re working on a right-side exhaust manifold on a V8 engine, refill the cooling system (see Tune-up and routine maintenance).
17. Start the engine and check for exhaust leaks between the manifold and cylinder head and between the manifold and exhaust pipe.