Although, in most cases, the engine is not equipped with factory-installed exhaust manifold gasket(s), such gaskets are available from auto parts stores.
REMOVAL & INSTALLATION
See Figures 1, 2, 3 and 4
- Remove the air cleaner.
- Remove the heat shroud from the exhaust manifold. On turbocharged models, remove the turbocharger.
- Place a block of wood under the exhaust pipe and disconnect the exhaust pipe from the exhaust manifold.
- Remove the exhaust manifold attaching nuts, bolts or studs and remove the manifold.
- Install a light coat of graphite grease on the exhaust manifold mating surface and position the manifold on the cylinder head.
- Install the exhaust manifold attaching nuts, bolts or studs and tighten them in two steps in the sequence shown. On 1979-86 engines, tighten them first to 5-7 ft. lbs., then tighten again to 16-23 ft. lbs. On 1987-88 engines, tighten them first to 15-17 ft. lbs., then tighten again to 20-30 ft. lbs.
- Connect the exhaust pipe to the exhaust manifold and remove the wood support from under the pipe.
- Install the air cleaner.
See Figure 5
- Remove the air cleaner and heat duct body.
- Disconnect the muffler inlet pipe and remove the choke hot air tube from the manifold.
- Remove the EGR tube and any other emission components which will interfere with manifold removal.
- Bend the exhaust manifold attaching bolt lock tabs back, remove the bolts and the manifold.
- Clean all manifold mating surfaces and place a new gasket on the muffler inlet pipe.
- Re-install the manifold by reversing the removal procedure. Torque the attaching bolts in the sequence shown to 18-24 ft. lbs.
See Figures 6 and 7
- If removing the right side exhaust manifold, remove the air cleaner and related parts and the heat stove, if so equipped.
- On 6-232, 8-255, and 8-302, dipstick and tube removal may be required. Remove any speed control brackets that interfere.
- Disconnect the exhaust manifold(s) from the muffler (or converter) inlet pipe(s).
On certain vehicles with automatic transmission and column shift, it may be necessary to disconnect the selector lever cross-shaft for clearance.
- Disconnect the spark plug wires and remove the spark plugs and heat shields. Disconnect the EGR sensor (models so equipped), and heat control valve vacuum line (models so equipped).
On some engines, the spark plug wire heat shields are removed with the manifold. Transmission dipstick tube and Thermactor air tube removal may be required on certain models. Air tube removal is possible by cutting the tube clamp at the converter.
- Remove the exhaust manifold attaching bolts and washers, and remove the manifold(s).
- Inspect the manifold(s) for damaged gasket surfaces, cracks, or other defects.
- Clean the mating surfaces of the manifold(s), cylinder head and muffler inlet pipe(s).
- Install the manifold(s) in reverse order of removal. Starting with the centermost bolt and working outward in both directions, torque the mounting bolts to the following values: