Engine & Engine Overhaul

ENGINE MECHANICAL

Exhaust Manifolds

1.2L Engine

Fig. 1: Exhaust manifold assembly-1.2L engine

Do not attempt to remove the exhaust manifold when the engine is hot. Allow adequate time for the engine to cool before removing.

1. Disconnect the negative battery cable.
2. Remove the bolts securing the heat shield to the exhaust manifold. Remove the heat shield.
3. Disconnect the O₂ sensor electrical harness.
4. If the manifold is being replaced, remove the O₂ sensor.
5. Remove the bolts securing the front exhaust pipe to the exhaust manifold. Remove the gasket.
6. Remove the six exhaust manifold-to-cylinder head mounting bolts.
7. Remove the exhaust manifold.
8. Clean all gasket material from both mating surfaces.

To install:

9. Install the exhaust manifold using new gaskets.
10. Install the manifold nuts and tighten to 14-22 ft. lbs. (20-29 Nm). Start tightening in the middle of the manifold and work toward the ends.
11. Using a new gasket connect the front exhaust pipe to the manifold. Install the bolts and tighten to 17-31 ft. lbs. (23-42 Nm).
12. Install the O₂ sensor, if removed, and connect the electrical harness.

When installing the O₂ sensor, make sure the threads are coated with anti-seize compound before installing.

13. Install the heat shield and install the mounting bolts. Tighten the bolts to 10-18 ft. lbs. (13-23 Nm).
14. Connect the negative battery cable.
15. Start the engine and check for exhaust leaks.

1.6L, 1.8L, 2.2L, 2.5L and 2.7L Engines

Fig. 2: Loosen and remove the exhaust manifold the exhaust-to-exhaust retainer nuts-2.2L engine shown

1. Disconnect the negative battery cable.
2. Disconnect the O₂ sensor electrical connector.
3. Remove the front under cover.
4. Remove the bolts securing the exhaust manifold covers and remove the covers.
5. Remove the front pipe-to-center pipe mounting nuts.
6. Remove the nuts that secure the exhaust pipe to the cylinder head and remove the exhaust pipe.
7. Discard the gaskets.

To install:

8. Clean all gasket surfaces completely.
9. Install the exhaust pipe to the cylinder head using new gaskets. Tighten the mounting nuts as follows:
   1. Turbocharged engines-28-33 ft. lbs. (34-44 Nm).
   2. Non-turbocharged engines-22-30 ft. lbs. (30-40 Nm).
10. Using new gaskets, connect the exhaust pipe to the center pipe. Tighten the mounting nuts as follows:
    1. Turbocharged engines-19-26 ft. lbs. (25-35 Nm).
    2. Non-turbocharged engines-9-17 ft. lbs. (13-23 Nm).
11. Install the exhaust manifold covers and cover mounting bolts.
12. Connect the O₂ sensor electrical connector.
13. Install the front under cover.
14. Lower the vehicle.
15. Connect the negative battery cable.
16. Start the engine and check for exhaust leaks.

3.3L Engine

Fig. 3: Loosen the EGR pipe attached to the exhaust manifold-3.3L engine

1. Disconnect the negative battery cable.
2. Disconnect the O₂ sensor electrical harness.
3. Remove the front undercover, if equipped.
4. Remove the bolts securing the exhaust manifold covers and remove.
5. Remove the front pipe-to-exhaust manifold mounting nuts.
6. Disconnect the EGR pipe from the exhaust manifold, only if the right side manifold is being removed.
7. Remove the exhaust manifold mounting nuts, then remove the exhaust manifold.
8. Clean all gasket material from both mating surfaces.

To install:

9. Install the exhaust manifold using new gaskets. Install the mounting nuts and tighten the nuts to 25-33 ft. lbs. (32-43 Nm).
10. Connect the EGR pipe to the right manifold, if disconnected.
11. Connect the exhaust pipe to the exhaust manifold and tighten the mounting nuts to 22-29 ft. lbs. (29-38 Nm).
12. Install the exhaust manifold covers and cover mounting bolts. Tighten the bolts to 13-15 ft. lbs. (17-19 Nm).
13. Install the front under cover.
14. Connect the O₂ sensor electrical harness.
15. Lower the vehicle.
16. Connect the negative battery cable.

END OF SECTION