Infiniti Car 1998-05

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Undercover and dust covers, if equipped
     
    Exhaust pipe at the manifold flange
     
    Air Injection Valve (AIV), AIV tube, and the attaching bracket, if equipped
     
    Exhaust Gas Recirculation (EGR) sensor electrical connection and the sensor
     
    Exhaust manifold cover
     
    Exhaust manifold nuts, starting at the outside and working towards the middle
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean the gasket mating surface and install a new exhaust manifold gasket.
  2.  
  3. Install or connect the following:

    Exhaust manifold. Torque the nuts in sequence, in 2 steps, to 27-35 ft. lbs. (37-48 Nm).
     
    Exhaust manifold cover and EGR sensor
     
    Exhaust gas sensor electrical connection
     
    AIV, AIV tube, and the attaching bracket, if equipped
     
    Exhaust pipe to the manifold flange. Torque the nuts to 30-35 ft. lbs. (41-48 Nm).
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Be sure to tighten the exhaust manifold nuts in the proper sequence-2002 2.0L engine

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If necessary, soak the exhaust pipe retaining nuts with penetrating oil to loosen them.



    Negative battery cable
     



    Engine cover, G35 only
     
    Air cleaner assembly and duct, G35 only
     
    Front exhaust pipe from the exhaust manifolds
     
    Heated Oxygen Sensors (HO 2 S) from the manifold, as necessary
     
    Protective covers from the manifolds
     
    Exhaust manifold-to-engine mounting nuts
     
    Manifold from the engine and discard the gaskets

    Click image to see an enlarged view

    Fig. Exhaust manifold tightening sequence. Use the reverse of the sequence for removal-G35 shown



    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components-G35 shown

     

  4.  

To install:

  1. Clean all gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the bolts, in sequence, in 2 steps to 21-23 ft. lbs. (28-32 Nm).
     
    Protective shields. Torque the bolts in 2 steps to 46-57 inch lbs. (5-6 Nm).
     
    HO 2 S to the manifold, as necessary
     
    Exhaust manifolds to the exhaust pipes. Torque the bolts/nuts to 32-37 ft. lbs. (43-50 Nm) for all models except G35. For the G35, torque the nuts to 45-48 ft. lbs. (60-66 Nm).
     
    Air cleaner assembly and engine cover, G35 only
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for exhaust leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Both battery cables
     
    Battery and tray
     
    Coolant reservoir tank and bracket
     
    Engine appearance cover
     
    Engine undercover
     
    Both oxygen sensor harnesses and sensors
     
    A/C compressor without disconnecting the refrigerant lines and set aside
     
    Left side exhaust front tube
     
    Steering column lower joint
     

  4.  
  5. Use a jack and raise the bottom of the engine.
  6.  
  7. Remove the left engine mounting insulator and the engine mounting brackets.
  8.  
  9. Remove the left manifold heat shield.
  10.  
  11. Remove the left manifold mounting nuts in the reverse order of the tightening sequence and remove the manifold and catalyst.
  12.  
  13. Remove the right side front exhaust tube.
  14.  
  15. Remove the nuts from the bottom right engine mounting insulator and lift the right side of the engine up about 1 and a half inches.
  16.  
  17. Remove the starter, then remove the right engine mounting insulator and mounting brackets.
  18.  
  19. Remove the right manifold mounting nuts in the reverse order of the tightening sequence and remove the manifold and catalyst.

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold assembly-Q45 and 2004 M45



    Click image to see an enlarged view

    Fig. Exhaust manifold tightening sequence-Q45 and 2004 M45

  20.  

To install:

  1. Clean the gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the nuts to 20-22 ft. lbs. (26-30 Nm) in two steps.
     

  4.  
  5. Install the starter, then install the right engine mounting insulator and mounting brackets. Tighten the bracket bolts to 25-31 ft. lbs. (35-43 Nm). Tighten the upper insulator nut to 32-40 ft. lbs. (43-553 Nm) and the lower nut to 65-72 ft. lbs. (87-98 Nm).
  6.  
  7. Install the heat shields.
  8.  
  9. Install the right side front exhaust tube.
  10.  
  11. Install the left engine mounting insulator and the engine mounting brackets and tighten the fasteners to the same specification as the right side.
  12.  
  13. Connect the steering column lower joint and tighten the bolt to 20 ft. lbs. (27 Nm).
  14.  
  15. Install the left side front exhaust tube.
  16.  
  17. Install or connect the following:

    A/C compressor
     
    Both oxygen sensor harnesses and sensors
     
    Engine undercover
     
    Engine appearance cover
     
    Coolant reservoir tank and bracket
     
    Battery and tray
     
    Both battery cables
     

  18.  
  19. Start the engine, check for leaks and repair if necessary.
  20.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Undercover and dust covers, if equipped
     
    Exhaust pipe at the manifold flange
     
    Air Injection Valve (AIV), AIV tube, and the attaching bracket, if equipped
     
    Exhaust Gas Recirculation (EGR) sensor electrical connection and the sensor
     
    Exhaust manifold cover
     
    Exhaust manifold nuts, starting at the outside and working towards the middle
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean the gasket mating surface and install a new exhaust manifold gasket.
  2.  
  3. Install or connect the following:

    Exhaust manifold. Torque the nuts in sequence, in 2 steps, to 27-35 ft. lbs. (37-48 Nm).
     
    Exhaust manifold cover and EGR sensor
     
    Exhaust gas sensor electrical connection
     
    AIV, AIV tube, and the attaching bracket, if equipped
     
    Exhaust pipe to the manifold flange. Torque the nuts to 30-35 ft. lbs. (41-48 Nm).
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  


    Click image to see an enlarged view

    Fig. Be sure to tighten the exhaust manifold nuts in the proper sequence-2.0L engines


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Undercover and dust covers, if equipped
     
    Exhaust pipe at the manifold flange
     
    Air Injection Valve (AIV), AIV tube, and the attaching bracket, if equipped
     
    Exhaust Gas Recirculation (EGR) sensor electrical connection and the sensor
     
    Exhaust manifold cover
     
    Exhaust manifold nuts, starting at the outside and working towards the middle
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean the gasket mating surface and install a new exhaust manifold gasket.
  2.  
  3. Install or connect the following:

    Exhaust manifold. Torque the nuts in sequence, in 2 steps, to 27-35 ft. lbs. (37-48 Nm)
     
    Exhaust manifold cover and EGR sensor
     
    Exhaust gas sensor electrical connection
     
    AIV, AIV tube, and the attaching bracket, if equipped
     
    Exhaust pipe to the manifold flange. Torque the nuts to 30-35 ft. lbs. (41-48 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Be sure to tighten the exhaust manifold nuts in the proper sequence-2.0L engines

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Undercover and dust covers, if equipped
     
    Exhaust pipe at the manifold flange
     
    Air Injection Valve (AIV), AIV tube, and the attaching bracket, if equipped
     
    Exhaust Gas Recirculation (EGR) sensor electrical connection and the sensor
     
    Exhaust manifold cover
     
    Exhaust manifold nuts, starting at the outside and working towards the middle
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean the gasket mating surface and install a new exhaust manifold gasket.
  2.  
  3. Install or connect the following:

    Exhaust manifold. Torque the nuts in sequence, in 2 steps, to 27-35 ft. lbs. (37-48 Nm)
     
    Exhaust manifold cover and EGR sensor
     
    Exhaust gas sensor electrical connection
     
    AIV, AIV tube, and the attaching bracket, if equipped
     
    Exhaust pipe to the manifold flange. Torque the nuts to 30-35 ft. lbs. (41-48 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Be sure to tighten the exhaust manifold nuts in the proper sequence-1998-2001 2.0L engines

  6.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If necessary, soak the exhaust pipe retaining nuts with penetrating oil to loosen them.



    Negative battery cable
     



    Exhaust manifolds from the exhaust pipes
     
    Protective covers from the manifolds
     
    Exhaust manifold-to-engine mounting nuts
     
    Manifold from the engine and discard the gaskets
     

  4.  

To install:

  1. Clean all gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the bolts in 2 steps to 22-24 ft. lbs. (30-32 Nm)
     
    Protective shields. Torque the bolts in 2 steps to 46-57 inch lbs. (5-6 Nm)
     
    Exhaust manifolds to the exhaust pipes. Torque the bolts to 32-37 ft. lbs. (43-50 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for exhaust leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If necessary, soak the exhaust pipe retaining nuts with penetrating oil to loosen them.



    Negative battery cable
     



    Exhaust manifolds from the exhaust pipes
     
    Protective covers from the manifolds
     
    Exhaust manifold-to-engine mounting nuts
     
    Manifold from the engine and discard the gaskets
     

  4.  

To install:

  1. Clean all gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the bolts in 2 steps to 22-24 ft. lbs. (30-32 Nm)
     
    Protective shields. Torque the bolts in 2 steps to 46-57 inch lbs. (5-6 Nm)
     
    Exhaust manifolds to the exhaust pipes. Torque the bolts to 32-37 ft. lbs. (43-50 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for exhaust leaks and repair if necessary.
  6.  

4.1L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercovers
     
    Exhaust pipe at the manifold flange
     
    Heat shield from the exhaust manifold, if equipped
     
    Exhaust Gas Recirculation (EGR) sensor electrical connection and if necessary, remove the sensor
     
    Exhaust manifold nuts, starting at the ends and working towards the center
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean the gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the nuts to 16-21 ft. lbs. (22-28 Nm).
     
    Heat shield on the exhaust manifold, if equipped
     


    Click image to see an enlarged view

    Fig. To avoid leaks, tighten the exhaust manifold nuts in the sequence shown-4.1L engine

    EGR sensor. Torque the fastener to 30-37 ft. lbs. (40-50 Nm), if removed.
     
    EGR sensor electrical connection
     
    Exhaust pipe to the manifold flange. Torque the nuts to 33-44 ft. lbs. (45-60 Nm).
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercovers
     
    Exhaust pipe at the manifold flange
     
    Heat shield from the exhaust manifold, if equipped
     
    Exhaust Gas Recirculation (EGR) sensor electrical connection and if necessary, remove the sensor
     
    Exhaust manifold nuts, starting at the ends and working towards the center
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean the gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the nuts to 16-21 ft. lbs. (22-28 Nm)
     
    Heat shield on the exhaust manifold, if equipped

    Click image to see an enlarged view

    Fig. To avoid leaks, tighten the exhaust manifold nuts in the sequence shown-4.1L engine

     
    EGR sensor. Torque the fastener to 30-37 ft. lbs. (40-50 Nm), if removed. Reconnect the sensor electrical connection
     
    Exhaust pipe to the manifold flange. Torque the nuts to 33-44 ft. lbs. (45-60 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercovers
     
    Exhaust pipe at the manifold flange
     
    Heat shield from the exhaust manifold, if equipped
     
    Exhaust Gas Recirculation (EGR) sensor electrical connection and if necessary, remove the sensor
     
    Exhaust manifold nuts, starting at the ends and working towards the center
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean the gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the nuts to 16-21 ft. lbs. (22-28 Nm)
     
    Heat shield on the exhaust manifold, if equipped

    Click image to see an enlarged view

    Fig. To avoid leaks, tighten the exhaust manifold nuts in the sequence shown-4.1L engine

     
    EGR sensor. Torque the fastener to 30-37 ft. lbs. (40-50 Nm), if removed. Reconnect the sensor electrical connection
     
    Exhaust pipe to the manifold flange. Torque the nuts to 33-44 ft. lbs. (45-60 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

4.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Both battery cables
     
    Battery and tray
     
    Coolant reservoir tank and bracket
     
    Engine appearance cover
     
    Engine undercovers
     
    Both oxygen sensor harnesses and sensors
     
    A/C compressor without disconnecting the refrigerant lines and set aside
     
    Left side exhaust front tube
     
    Steering column lower joint
     

  4.  
  5. Use a jack and raise the bottom of the engine.
  6.  
  7. Remove the left engine mounting insulator and the engine mounting brackets.
  8.  
  9. Remove the left manifold heat shield.
  10.  
  11. Remove the left manifold mounting nuts in the reverse order of the tightening sequence and remove the manifold and catalyst.
  12.  
  13. Remove the right side front exhaust tube.
  14.  
  15. Remove the nuts from the bottom right engine mounting insulator and lift the right side of the engine up about 1 and a half inches.
  16.  
  17. Remove the starter, then remove the right engine mounting insulator and mounting brackets.
  18.  
  19. Remove the right manifold mounting nuts in the reverse order of the tightening sequence and remove the manifold and catalyst.
  20.  


    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold assembly-4.5L engine



    Click image to see an enlarged view

    Fig. Exhaust manifold tightening sequence-4.5L engine


To install:

  1. Clean the gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the nuts to 20-22 ft. lbs. (26-30 Nm) in two steps.
     

  4.  
  5. Install the starter, then install the right engine mounting insulator and mounting brackets. Tighten the bracket bolts to 25-31 ft. lbs. (35-43 Nm). Tighten the upper insulator nut to 32-40 ft. lbs. (43-553 Nm) and the lower nut to 65-72 ft. lbs. (87-98 Nm).
  6.  
  7. Install the heat shields.
  8.  
  9. Install the right side front exhaust tube.
  10.  
  11. Install the left engine mounting insulator and the engine mounting brackets and tighten the fasteners to the same specification as the right side.
  12.  
  13. Connect the steering column lower joint and tighten the bolt to 20 ft. lbs. (27 Nm).
  14.  
  15. Install the left side front exhaust tube.
  16.  
  17. Install or connect the following:

    A/C compressor
     
    Both oxygen sensor harnesses and sensors
     
    Engine undercovers
     
    Engine appearance cover
     
    Coolant reservoir tank and bracket
     
    Battery and tray
     
    Both battery cables
     

  18.  
  19. Start the engine, check for leaks and repair if necessary.
  20.  

 
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