REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10
On turbocharged engines, the turbocharger and exhaust manifold are removed as a unit. For exhaust manifold removal on engines so equipped, please refer to the Turbocharger Removal and Installation procedure which follows later in this section.
- On carbureted engines, disconnect the hot air duct from the exhaust manifold insulator assembly (heat stove).
- Disconnect the secondary air pipe assembly at the exhaust manifold, and position the pipes out of the way.
- Disconnect the oxygen sensor's electrical lead. Unscrew and remove the sensor, if necessary.
If both the manifold and sensor are to be re-used, the oxygen sensor need not be removed.
- Remove the insulator assembly from the exhaust manifold.
- Remove the exhaust pipe or front catalytic converter attaching nuts, then disconnect the exhaust pipe or converter.
- Unfasten the exhaust manifold attaching nuts, then remove the manifold and gaskets.
- Check the manifold for distortion with a metal straight edge and a feeler gauge as described under Cylinder Head Overhaul. Repair or replace as necessary.
- Position new gasket(s) and the manifold over the mounting studs. Torque the nuts to specification in several stages, working from the center outwards.
- Connect and fasten the exhaust pipe/front catalytic converter to the manifold, using a new gasket.
- Position and fasten the insulator assembly over the manifold. Install the fitting for the secondary air pipe assembly.
- Coat the threads with anti-seize compound and install the oxygen sensor, if applicable. Reconnect the electrical lead.
- Position the secondary air pipe assembly and connect it to the manifold fitting. Fasten any retaining brackets or clamps.
- On carbureted engines, connect the hot air duct to the insulator assembly.