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. Torque the 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. Torque the new nuts to 38 ft. lbs. (52 Nm)
   • (O2S) connector
   • EGR pipe. Torque the pipe to 34 ft. lbs. (47 Nm)
   • Heat shield. Torque the bolts to 88 inch lbs. (10 Nm)
   • Water bypass pipe. Torque 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. Torque the bolts to 17 ft. lbs. (23 Nm)
   • Exhaust pipe flange using a new gasket. Torque 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. Torque the bolts to 12-16 ft. lbs. (16-22 Nm)
   • Heat shield. Torque 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. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
   • EGR pipe, if installing the rear (right side) manifold
   • Exhaust pipes using new gaskets. Torque 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. Torque the nuts to 15-20 ft. lbs. (20-28 Nm) and the bolts to 12-16 ft. lbs. (16-22 Nm)
   • Heat shield. Torque the bolts to 89 inch lbs. (10 Nm)
   • EGR pipe, If installing the rear (right side) manifold
   • Exhaust pipes using new gaskets. Torque the nuts to 38 ft. lbs. (51 Nm)
   • O2S connectors
   • Negative battery cable