Aurora 2001-2003

Exhaust Manifold

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Removal & Installation



3.5L Engine
Left Side (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Cooling fans
     
    Oil level indicator tube
     
    Heat shield from the manifold
     
    Exhaust manifold bolts
     
    Exhaust manifold-to-crossover pipe studs
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Heat shield
     
    Oil level indicator tube
     
    Cooling fans
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  

Right Side (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Cruise control cable from the throttle body lever and bracket and position aside
     
    Accelerator cable from the throttle body lever and bracket and position aside
     
    Air cleaner intake duct
     
    Air cleaner assembly
     
    Fasteners attaching the accelerator control cable bracket to the throttle body
     
    Accelerator control cable bracket
     
    Vacuum brake booster
     
    Transaxle filler tube
     
    Transaxle range selector cable
     
    Bolt connecting the ground lead to the top of the transaxle
     
    Connector C101 at the left strut tower
     
    Left wheel speed sensor connector
     
    Left wheel speed sensor lead from the retaining brackets
     
    Connector C100 at the top of the transaxle
     
    Harness from the harness clip and position aside
     
    Bolts attaching the exhaust manifold heat shield to the left exhaust manifold and position aside
     
    Right exhaust manifold crossover bolts
     
    Two bolts attaching the left exhaust manifold to the right exhaust manifold crossover
     
    Exhaust manifold pipe
     
    Right exhaust manifold studs
     
    Heated Oxygen Sensor (HO 2 S)
     
    Exhaust Gas Recirculation (EGR) inlet pipe from the right exhaust manifold
     
    Right exhaust manifold retaining bolts
     
    Right exhaust manifold and the gasket from the engine and discard the gasket
     
    Exhaust manifold crossover seal from the left exhaust manifold and discard the seal

    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold-3.5L engine

     

  6.  

To install:

  1. Install a new exhaust manifold crossover seal over the left exhaust manifold
  2.  
  3. Align the exhaust manifold to the cylinder head.
  4.  
  5. Place the crossover portion of the exhaust manifold around the left exhaust manifold.
  6.  
  7. Hold the exhaust manifold to the right cylinder head using a retaining bolt.
  8.  
  9. Grasp the exhaust manifold and remove the retaining bolt.
  10.  
  11. Place a new exhaust manifold gasket between the exhaust manifold and the cylinder head.
  12.  
  13. Install or connect the following:
    NOTE
    Make sure the throttle should operate freely without binding between full closed and wide open throttle.



    Right exhaust manifold bolts and tighten to 18 ft. lbs. (25 Nm)
     
    EGR inlet pipe to the exhaust manifold nut to 44 ft. lbs. (60 Nm)
     
    Right exhaust manifold studs and tighten to 80 inch. lbs. ( Nm)
     
    HO 2 S
     
    Exhaust manifold pipe
     
    Two bolts attaching the left exhaust manifold to the right exhaust manifold crossover and tighten to 18 ft. lbs. (25 Nm)
     
    Heat shield to the left exhaust manifold and tighten the bolts to 80 inch. lbs. (9 Nm)
     
    Harness to the harness clip
     
    C100 to the transaxle
     
    Left wheel speed sensor connector
     
    Left wheel speed sensor lead to the retaining brackets
     
    C101 at the left strut tower
     
    Bolt connecting the ground lead to the top of the transaxle and tighten to 13 ft. lbs. (17 Nm)
     
    Transaxle range selector cable
     
    Transaxle filler tube
     
    Accelerator control cable bracket to the throttle body
     
    Fasteners attaching the accelerator control cable bracket to the throttle body. Tighten the accelerator control cable bracket bolt and to 115 inch. lbs. (13 Nm) and the accelerator control cable bracket nuts to 89 inch lbs. (10 Nm).
     
    Air cleaner assembly
     
    Air cleaner intake duct
     



    Accelerator cable to the throttle body lever and bracket
     
    Cruise control cable to the throttle body lever and bracket
     

  14.  

4.0L Engine
Left Side (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Two nuts attaching the secondary AIR tube to the exhaust manifold
     
    Secondary AIR tube and the gasket from the exhaust manifold and discard the gasket
     
    Front engine mount bracket
     
    Oxygen Sensor (O 2 S), if necessary
     
    Two bolts attaching the left exhaust manifold to the front exhaust manifold pipe
     
    Exhaust manifold retaining bolts
     
    Exhaust manifold and the gasket from the engine and discard the gasket
     
    Front exhaust manifold pipe seal from the left exhaust manifold and discard the seal
     
    Exhaust manifold flange seal retainer
     

  4.  

To install:

  1. Install or connect the following:

    Retainer and a new front exhaust manifold pipe seal over the exhaust manifold
     
    New exhaust manifold gasket between the exhaust manifold and the cylinder head
     
    Exhaust manifold into the front exhaust manifold pipe and up to the cylinder head
     
    Left exhaust manifold bolts and tighten to 18 ft. lbs. (25 Nm)
     
    Two bolts attaching the left exhaust manifold to the front exhaust manifold pipe and tighten to 18 ft. lbs. (25 Nm)
     
    O 2 S
     
    New gasket to the secondary AIR tube
     
    Two nuts attaching the secondary AIR tube to the exhaust manifold and tighten to 106 inch lbs. (12 Nm)
     

  2.  

Right Side (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Cruise control cable from the throttle body lever and bracket and position aside
     
    Accelerator cable from the throttle body lever and bracket and position aside
     
    Air cleaner intake duct
     
    Air cleaner assembly
     
    Fasteners attaching the accelerator control cable bracket to the throttle body
     
    Accelerator control cable bracket
     
    Vacuum brake booster
     
    Transaxle filler tube
     
    Transaxle range selector cable
     
    Bolt connecting the ground lead to the top of the transaxle
     
    Connector C101 at the left strut tower
     
    Left wheel speed sensor connector
     
    Left wheel speed sensor lead from the retaining brackets
     
    Connector C100 at the top of the transaxle
     
    Harness from the harness clip and position aside
     
    Bolts attaching the exhaust manifold heat shield to the left exhaust manifold and position aside
     
    Right exhaust manifold crossover bolts
     
    Two bolts attaching the left exhaust manifold to the right exhaust manifold crossover
     
    Exhaust manifold pipe
     
    Right exhaust manifold studs
     
    Heated Oxygen Sensor (HO 2 S)
     
    Exhaust Gas Recirculation (EGR) inlet pipe from the right exhaust manifold
     
    Right exhaust manifold retaining bolts
     
    Right exhaust manifold and the gasket from the engine and discard the gasket
     
    Exhaust manifold crossover seal from the left exhaust manifold and discard the seal
     

  6.  

To install:

  1. Install a new exhaust manifold crossover seal over the left exhaust manifold
  2.  
  3. Align the exhaust manifold to the cylinder head.
  4.  
  5. Place the crossover portion of the exhaust manifold around the left exhaust manifold.
  6.  
  7. Hold the exhaust manifold to the right cylinder head using a retaining bolt.
  8.  
  9. Grasp the exhaust manifold and remove the retaining bolt.
  10.  
  11. Place a new exhaust manifold gasket between the exhaust manifold and the cylinder head.
  12.  
  13. Install or connect the following:
    NOTE
    Make sure the throttle should operate freely without binding between full closed and wide open throttle.



    Right exhaust manifold bolts and tighten to 18 ft. lbs. (25 Nm)
     
    EGR inlet pipe to the exhaust manifold nut to 44 ft. lbs. (60 Nm)
     
    Right exhaust manifold studs and tighten to 80 inch. lbs. ( Nm)
     
    HO 2 S
     
    Exhaust manifold pipe
     
    Two bolts attaching the left exhaust manifold to the right exhaust manifold crossover and tighten to 18 ft. lbs. (25 Nm)
     
    Heat shield to the left exhaust manifold and tighten the bolts to 80 inch. lbs. (9 Nm)
     
    Harness to the harness clip
     
    C100 to the transaxle
     
    Left wheel speed sensor connector
     
    Left wheel speed sensor lead to the retaining brackets
     
    C101 at the left strut tower
     
    Bolt connecting the ground lead to the top of the transaxle and tighten to 13 ft. lbs. (17 Nm)
     
    Transaxle range selector cable
     
    Transaxle filler tube
     
    Accelerator control cable bracket to the throttle body
     
    Fasteners attaching the accelerator control cable bracket to the throttle body. Tighten the accelerator control cable bracket bolt and to 115 inch. lbs. (13 Nm) and the accelerator control cable bracket nuts to 89 inch lbs. (10 Nm).
     
    Air cleaner assembly
     
    Air cleaner intake duct
     



    Accelerator cable to the throttle body lever and bracket
     
    Cruise control cable to the throttle body lever and bracket
     

  14.  

 
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