Astro, Safari 1997-2005

Exhaust Manifold

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Removal & Installation



Left Side Exhaust Manifold
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Left front tire
     
    Left fender wheelhouse extension
     
    Catalytic converter assembly
     
    Spark plug wires
     
    Spark plug wire support bolts
     
    Spark plug wire support with the wires
     
    Front 4 exhaust manifold bolts through the wheelhouse
     
    Rear 2 manifold bolts from the engine cover opening
     
    Exhaust manifold, gasket and spark plug wire shields from underneath the vehicle
     

  4.  

To install:


NOTE
To aid the exhaust manifold installation, the tabs on a new manifold gasket will hold the gasket and bolts in place.

  1. Using a plastic scraper, clean the gasket mounting surfaces.
  2.  
  3. Install new gaskets, spark plug wire shield and bolts to the manifold, making sure the bolts are held in place by the gasket tabs.
  4.  
  5. Install or connect the following:


  6.  
  7. Exhaust manifold. Tighten the bolts to 11 ft. lbs. (15 Nm), then to 22 ft. lbs. (30 Nm).
    NOTE
    Tighten the 2 rear bolts through the engine cover opening and the front 4 bolts through the wheelhouse.



    Spark plug wires
     
    Catalytic converter
     
    Fender wheelhouse extension
     
    Front tire
     
    ECT sensor electrical connector
     
    Negative battery cable
     

  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Once the engine has cooled sufficiently, install the engine cover to the passenger compartment.
  12.  

 
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