Aura, Outlook 2007

Exhaust Manifold

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Removal & Installation



2.4L Engines
  1. Remove the exhaust manifold heat shield.
  2.  
  3. Remove the Heated Oxygen Sensor (HO2S).
  4.  
  5. Remove the exhaust manifold pipe.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the upper exhaust manifold brace bolt.
  10.  
  11. Remove and discard the exhaust manifold nuts.
  12.  
  13. Remove the exhaust manifold/catalytic converter assembly.
  14.  
  15. Remove and discard the exhaust manifold gasket.
  16.  

To install:

  1. Install a NEW exhaust manifold gasket onto the manifold studs.
  2.  
  3. Install the exhaust manifold/catalytic converter assembly.
  4.  
  5. Install the NEW exhaust manifold nuts finger tight.
  6.  
  7. Install the upper exhaust manifold brace bolt to 43 ft. lbs. (58 Nm).
  8.  
  9. Tighten the manifold bolts in the sequence shown to 10 ft. lbs. (14 Nm).
  10.  
  11. Raise and suitably support the vehicle.
  12.  
  13. Install the exhaust manifold pipe.
  14.  
  15. Install the HO2S.
  16.  
  17. Install the exhaust manifold heat shield.

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-2.4L engine

  18.  

3.5L Engine
Left Side
  1. Remove the heated oxygen sensor.
  2.  
  3. Remove the spark plug wires from the spark plugs and set aside.
  4.  
  5. Remove the spark plugs.
  6.  
  7. Remove the exhaust manifold heat shield bolts.
  8.  
  9. Remove the exhaust manifold heat shield.
  10.  
  11. Remove the exhaust manifold bolts.
  12.  
  13. Remove the exhaust manifold.
  14.  
  15. Remove the exhaust manifold gasket.
  16.  

To install:

  1. Install the exhaust manifold gasket.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold bolts. Tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the exhaust manifold heat shield.
  8.  
  9. Install the spark plugs.
  10.  
  11. Install the spark plug wires.
  12.  
  13. Install the heated oxygen sensor and tighten to 31 ft. lbs. (42 Nm).
  14.  

Right Side
  1. Remove the heated oxygen sensor.
  2.  
  3. Remove the spark plug wires.
  4.  
  5. Remove the spark plugs.
  6.  
  7. Remove the exhaust manifold heat shield bolts.
  8.  
  9. Remove the exhaust manifold heat shields.
  10.  
  11. Remove the exhaust manifold bolts.
  12.  
  13. Remove the exhaust manifold.
  14.  
  15. Remove the exhaust manifold gasket.
  16.  

To install:

  1. Install the exhaust manifold gasket.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold bolts. Tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the exhaust manifold heat shield.
  8.  
  9. Install the spark plugs.
  10.  
  11. Install the spark plug wires.
  12.  
  13. Install the heated oxygen sensor and tighten to 31 ft. lbs. (42 Nm).
  14.  

3.6L Engine
Left Side
  1. Remove the left exhaust manifold heat shield bolts.
  2.  
  3. Remove the left exhaust manifold heat shield.
  4.  
  5. Remove the Engine Coolant Temperature (ECT) sensor.
  6.  
  7. Remove the left exhaust manifold lower bolts from the left cylinder head.
  8.  
  9. Remove the left exhaust manifold upper bolts from the left cylinder head.
  10.  
  11. Remove the left exhaust manifold.
  12.  
  13. Remove and discard the left exhaust manifold gasket.
  14.  

To install:

  1. Install a NEW left exhaust manifold gasket.
  2.  
  3. Install the left exhaust manifold.
  4.  
  5. Loosely install the left exhaust manifold upper bolts into the left cylinder head. Tighten the left exhaust manifold bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the Engine Coolant Temperature (ECT) sensor. Tighten to 16 ft. lbs. (22 Nm).
  8.  
  9. Install the exhaust manifold heat shield and bolts. Tighten to 18 in. lbs. (10 Nm).
  10.  

Right Side
  1. Remove the right exhaust manifold heat shield bolts.
  2.  
  3. Remove the right exhaust manifold heat shield.
  4.  
  5. Remove the right exhaust manifold lower bolts from the right cylinder head.
  6.  
  7. Remove the right exhaust manifold upper bolts from the right cylinder head.
  8.  
  9. Remove the right exhaust manifold.
  10.  
  11. Remove and discard the right exhaust manifold gasket.
  12.  
  13. Remove the right knock sensor heat shield bolts.
  14.  
  15. Remove the right knock sensor heat shield.
  16.  
  17. Remove the right knock sensor bolt.
  18.  
  19. Remove the right knock sensor.
  20.  
  21. Remove the Crankshaft Position (CKP) sensor bolt.
  22.  
  23. Remove the CKP sensor.
  24.  
  25. Remove and discard the CKP sensor O-ring.
  26.  
  27. Remove the engine block heater, if equipped.
  28.  

To install:

  1. Install the engine block heater, if equipped.
  2.  
  3. Install a NEW Crankshaft Position (CKP) sensor O-ring.
  4.  
  5. Install the CKP sensor.
  6.  
  7. Install the CKP sensor bolt. Tighten to 89 in. lbs. (10 Nm).
  8.  
  9. Install the right knock sensor.

    Click image to see an enlarged view

    Fig. Install the right knock sensor bolt. Ensure the knock sensor is oriented with the harness connector positioned to the front on the right side (1)-3.6L engine

  10.  
  11. Install the right knock sensor bolt. Ensure the knock sensor is oriented with the harness connector positioned to the front on the right side. Tighten the sensor bolt to 17 ft. lbs. (23 Nm).
  12.  
  13. Install the right knock sensor heat shield.
  14.  
  15. Install the right knock sensor heat shield bolts. Ensure the small M6 bolt is installed at the rear and the large M10 bolt is installed at the front.
  16.  
  17. Tighten the right knock sensor heat shield M10 bolt to 37 ft. lbs. (50 Nm).
  18.  
  19. Tighten the right knock sensor heat shield M6 bolt to 89 in. lbs. (10 Nm).
  20.  
  21. Install a NEW right exhaust manifold gasket.
  22.  
  23. Install the right exhaust manifold.
  24.  
  25. Loosely install the right exhaust manifold bolts into the right cylinder head.
  26.  
  27. Tighten the right exhaust manifold bolts to 18 ft. lbs. (25 Nm).
  28.  
  29. Install the exhaust manifold heat shield and bolts, tighten to 89 in. lbs. (10 Nm).
  30.  

 
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