Table of contents: Removal ↓ Front manifold (from the radiator…↓ Rear manifold (from the engine…↓ Installation ↓
Attention! Proceed with the procedure only after the power unit has completely cooled down.
Removal
1. Disconnect the negative cable from the battery.
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery! Jack up the car and support it.
2. Soak the manifold fasteners with penetrating oil.
3. Working under the vehicle, disconnect the Y-shaped exhaust pipe ("pants") from the exhaust manifolds (see Chapter Power and exhaust systems).
Front manifold (from the radiator side)
1. Remove the air intake duct assembly from the throttle body with the upper half of the air cleaner housing (see Chapter Power and exhaust systems).
2. Disconnect the EGR hose from the exhaust manifold.
3. To gain access to the manifold fasteners, remove the engine oil dipstick guide tube mounting bracket. Loosen the top row of mounting nuts.
4. Working from the edges to the center, loosen the bottom row of fasteners and remove the manifold from the engine.
Rear manifold (from the engine compartment bulkhead side)
Working under the vehicle, loosen the mounting nuts and remove the manifold.
Installation
1. Carefully inspect the manifolds and their fastening elements, checking the components for cracks, deformations and other mechanical damage.
2. Scrape off carbon deposits and traces of old gasket material from the mating surfaces of the manifolds and cylinder heads. If there have been exhaust leaks, assess the non-flatness of the mating surfaces of the manifolds (use an edge-mounted steel ruler and a blade-type feeler gauge). Compare the measurement results with the requirements of the Specifications, if necessary, give the collectors a groove.
3. Place new gaskets on the manifold mounting studs.
4. Install the manifolds and tighten the nuts that secure them.
5. Working from the center outward, tighten the fasteners evenly to the required torque in three to four stages.
6. Install the remaining components in the reverse order of their removal. Remember to replace the sealing gaskets when connecting the exhaust inlet pipe to the front manifold.
7. Start the engine and check it for signs of exhaust leaks.