Nissan Stanza/200SX/240SX 1982-1992 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



All Models (Except 200SX with VG30 Engine)

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Exhaust manifold torque sequence - KA24E engine

  1. Remove the air cleaner assembly, if necessary for access. Remove the heat shield.
  2.  
  3. Disconnect and tag the high tension wires from the spark plugs on the exhaust side of the engine.
  4.  
  5. Disconnect the exhaust pipe from the exhaust manifold. On turbocharged engines remove the exhaust pipe from the turbocharger assembly.
  6.  

Soak the exhaust pipe retaining bolts with penetrating oil if necessary to loosen them.

  1. On the carbureted models, remove the air induction and/or the EGR tubes from the exhaust manifold. On the fuel injected models, disconnect the exhaust gas sensor electrical connector.
  2.  
  3. Remove the exhaust manifold mounting nuts and the manifold from the cylinder head.
  4.  

To install:
  1. Using a putty knife or equivalent, clean the gasket mounting surfaces.
  2.  
  3. Install the manifold onto the engine, use new gaskets and from the, center working to the end. Torque the exhaust manifold nuts/bolts EVENLY to 14-22 ft. lbs.
  4.  
  5. Install the air induction and/or the EGR tubes to the exhaust manifold or the exhaust gas sensor electrical connector.
  6.  
  7. Reconnect exhaust pipe. On turbocharged engines reconnect the exhaust pipe to the turbocharger assembly.
  8.  
  9. Connect spark plug wires and air cleaner and any related hoses.
  10.  
  11. Start engine and check for exhaust leaks.
  12.  

200SX (VG30E Engine)

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Exhaust manifold torque sequence - VG30E engine

  1. Remove the exhaust manifold sub-cover and manifold cover. Remove the EGR tube from the right side exhaust manifold. Remove the exhaust manifold stay.
  2.  
  3. Disconnect the left side exhaust manifold at the exhaust pipe by removing retaining nuts and disconnect the right side manifold from the connecting pipe.
  4.  

Soak the exhaust pipe retaining bolts with penetrating oil if necessary to loosen them.

  1. Remove bolts for each manifold in the order shown.
  2.  

To install:
  1. Clean all gasket surfaces. Install new gaskets.
  2.  
  3. Install the manifold to the engine, torquing manifold bolts alternately in two stages in the exact reverse order of removal to 13-16 ft. lbs.
  4.  
  5. Reconnect the exhaust pipe and the connecting pipe. Be careful not break these bolts.
  6.  
  7. Install the exhaust manifold stay and the EGR tube to the right side manifold.
  8.  
  9. Install the exhaust manifold covers. Start the engine and check for exhaust leaks.
  10.  

 
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