Exhaust Manifold

REMOVAL & INSTALLATION

1.5L and 1.8L (BP) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Air cleaner and air hose
   • Water bypass pipe bolt
   • Exhaust manifold heat shield bolts and the heat shield
   • Oxygen (O2S) sensor electrical connector
   • Exhaust pipe-to-exhaust manifold nuts and discard them.
   • Exhaust Gas Recirculation (EGR) pipe from the exhaust manifold
   • Exhaust manifold nuts and bolts and discard the nuts
   • Exhaust manifold

   To install:

3. Clean all gasket mating surfaces.
4. Install or connect the following:
   • Exhaust manifold. Tighten the nuts/bolts to 14–16 ft. lbs. (19–22 Nm) on the 1.5L engine or to 29–34 ft. lbs. (39–47 Nm) on the 1.8L engine.
   • Exhaust pipe. Tighten the new nuts to 38 ft. lbs. (52 Nm).
   • (O2S) connector
   • EGR pipe. Tighten the pipe to 34 ft. lbs. (47 Nm).
   • Heat shield. Tighten the bolts to 88 inch lbs. (10 Nm).
   • Water bypass pipe. Tighten the bolt to 48–65 ft. lbs. (64–89 Nm).
   • Air hose and air cleaner
   • Negative battery cable

1.6L and 1.8L (FP) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Air cleaner and hose assembly
   • Water bypass pipe-to-engine block bolt
   • Exhaust Gas Recirculation (EGR) pipe
   • Oxygen (O2S) sensor from the exhaust system
   • Front exhaust pipe from the Warm-Up Three Way Catalytic (WU-TWC) converter
   • Exhaust manifold insulator
   • Warm-Up Three Way Catalytic (WU-TWC) converter from the manifold
   • Exhaust manifold

   To install:

3. Be sure all gasket mating surfaces are clean prior to assembly.
4. Tighten the components following the illustration.
5. Install or connect the following:
   • Exhaust manifold
   • Warm-Up Three Way Catalytic (WU-TWC) converter to the manifold
   • Exhaust manifold insulator
   • Front exhaust pipe from the Warm-Up Three Way Catalytic (WU-TWC) converter
   • Oxygen (O2S) sensor to the exhaust system
   • EGR pipe
   • Water bypass pipe-to-engine block bolt
   • Air cleaner and hose assembly
   • Negative battery cable

     Fig. 1: Exploded view of the exhaust system — 1.6L and 1.8L (FP) engines

2.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Exhaust manifold insulator
   • Oxygen (O2S) sensor electrical connector
   • Oxygen (O2S) sensor, if necessary
   • Exhaust Gas Recirculation (EGR) pipe, if equipped
   • Exhaust pipe flange nuts
   • Exhaust pipe from the manifold
   • Exhaust manifold

   To install:

3. Be sure all gasket mating surfaces are clean prior to assembly.
4. Install or connect the following:
   • Exhaust manifold using a new gasket. Tighten the nuts/bolts to 17 ft. lbs. (23 Nm).
   • Exhaust pipe flange using a new gasket. Tighten the nuts to 34 ft. lbs. (46 Nm).
   • Exhaust Gas Recirculation (EGR) pipe, if equipped
   • Oxygen (O2S) sensor, if necessary
   • Oxygen (O2S) sensor electrical connector
   • Exhaust manifold insulator
   • Negative battery cable

2.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Front and rear exhaust pipe nuts and lower the exhaust system

   NOTE: Both pipes must be disconnected, even if only one manifold is to be removed.

   • Exhaust Gas Recirculation (EGR) pipe, if removing the rear (right side) manifold
   • Charge air cooler and coolant/condenser fans, If removing the front (left side) manifold
   • Front and rear Oxygen (O2S) sensor connectors
   • 3 heat shield bolts and the heat shield
   • Exhaust manifold

   To install:

3. Clean all gasket mating surfaces.
4. Install or connect the following:
   • Exhaust manifold using a new gasket. Tighten the nuts/bolts to 12–16 ft. lbs. (16–22 Nm).
   • Heat shield. Tighten the bolts to 70–95 inch lbs. (8–11 Nm).
   • O2S connectors
   • Coolant/condenser fans and the charge air cooler, if installing the front (left side) manifold. Tighten the bolts to 14–18 ft. lbs. (19–25 Nm).
   • EGR pipe, if installing the rear (right side) manifold.
   • Exhaust pipes using new gaskets. Tighten the nuts to 28–38 ft. lbs. (38–51 Nm).
   • Negative battery cable

2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Oxygen (O2S) sensor connectors

     Fig. 2: Exploded view of the exhaust manifolds — 2.5L engine, 2.3L engine is similar

   • Front and rear exhaust pipe nuts and lower the exhaust system

   NOTE: Both pipes must be disconnected, even if only one manifold is to be removed.

   • Exhaust Gas Recirculation (EGR) pipe, if removing the rear (right side) manifold
   • 3 heat shield bolts and the heat shield
   • 2 nuts and 5 bolts and the exhaust manifold

   To install:

3. Clean all gasket mating surfaces.
4. Install or connect the following:
   • Exhaust manifold using a new gasket. Tighten the nuts to 15–20 ft. lbs. (20–28 Nm) and the bolts to 12–16 ft. lbs. (16–22 Nm).
   • Heat shield.
5. Tighten the bolts to 88 inch lbs. (10 Nm).
6. EGR pipe, If installing the rear (right side) manifold
7. Exhaust pipes using new gaskets. Tighten the nuts to 38 ft. lbs. (51 Nm).
8. O2S connectors
9. Negative battery cable