Nissan Frontier, Xterra 1998-05

Exhaust Manifold

Print

Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the quick connector cap and disconnect the quick connector at the engine side.
  8.  
  9. Remove the air duct and PCV hose.
  10.  
  11. Remove the electric throttle control actuator retaining bolts. Be sure to remove the bolts by reversing the order of the tightening torque sequence.
  12.  
  13. Remove the electric throttle control actuator and gasket.
  14.  
  15. Disconnect the harness connector of the air fuel ratio sensor and the harness from the bracket and middle clamp. Remove the air fuel ratio sensor using tool J-44626, or equivalent.
    NOTE
    Be careful not to damage the air fuel ratio sensor. Discard the sensor if it has been dropped from a height of more than 19.7 inches on to a hard surface.

  16.  
  17. Remove the front exhaust tube. Remove the exhaust manifold cover.
  18.  
  19. Remove the bracket between the exhaust manifold three way catalyst assembly and the transmission assembly.
  20.  
  21. Remove the exhaust manifold retaining bolts. Be sure to remove the bolts by reversing the order of the tightening torque sequence.
  22.  
  23. Remove the exhaust manifold from the engine. Discard the gasket.
  24.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold bolt torque sequence-2.5L engine

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new gaskets.
  4.  
  5. Be sure to tighten the exhaust manifold retaining bolts to specification and in the proper sequence.
    NOTE
    Before installing a new air fuel sensor apply anti seize lubricant to the threads. Do not over torque the sensor, doing so may cause damage to the sensor resulting in the MIL light coming on.


    NOTE
    See throttle valve closed position learning and idle air volume learning procedures, for relearning information.

  6.  

3.3L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Heated Oxygen (HO2S) sensor connectors
     
    Exhaust front pipes
     
    Exhaust manifolds with catalytic converters attached. Loosen the nuts in the reverse of the torque sequence.
     

  4.  

To install:



Click image to see an enlarged view

Fig. Exhaust manifold torque sequence-3.3L engine

  1. Install or connect the following:

    Exhaust manifolds with catalytic converters attached. Tighten the nuts in sequence to 21-25 ft. lbs. (28-33 Nm).
     
    Exhaust front pipes. Tighten the bolts to 21-25 ft. lbs. (28-33 Nm).
     
    Heated Oxygen (HO2S) sensor connectors
     
    EGR tube. Tighten the flange fittings to 29-36 ft. lbs. (39-49 Nm).
     
    Exhaust manifold heat shields. Tighten the bolts to 84-96 inch lbs. (9-11 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  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
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust front pipes
     
    Exhaust manifolds with catalytic converters attached. Loosen the nuts in the reverse of the torque sequence.
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold torque sequence-3.3L engine

  1. Install or connect the following:

    Exhaust manifolds with catalytic converters attached. Tighten the nuts in sequence to 21-25 ft. lbs. (28-33 Nm).
     
    Exhaust front pipes. Tighten the bolts to 21-25 ft. lbs. (28-33 Nm).
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    EGR tube. Tighten the flange fittings to 29-36 ft. lbs. (39-49 Nm).
     
    Exhaust manifold heat shields. Tighten the bolts to 84-96 inch lbs. (9-11 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  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
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust front pipes
     
    Exhaust manifolds with catalytic converters attached. Loosen the nuts in the reverse of the torque sequence.
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold torque sequence-3.3L engine

  1. Install or connect the following:

    Exhaust manifolds with catalytic converters attached. Tighten the nuts in sequence to 21-25 ft. lbs. (28-33 Nm).
     
    Exhaust front pipes. Tighten the bolts to 21-25 ft. lbs. (28-33 Nm).
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    EGR tube. Tighten the flange fittings to 29-36 ft. lbs. (39-49 Nm).
     
    Exhaust manifold heat shields. Tighten the bolts to 84-96 inch lbs. (9-11 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  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
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust front pipes
     
    Exhaust manifolds with catalytic converters attached. Loosen the nuts in the reverse of the torque sequence.
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold torque sequence-3.3L engine

  1. Install or connect the following:

    Exhaust manifolds with catalytic converters attached. Tighten the nuts in sequence to 21-25 ft. lbs. (28-33 Nm).
     
    Exhaust front pipes. Tighten the bolts to 21-25 ft. lbs. (28-33 Nm).
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    EGR tube. Tighten the flange fittings to 29-36 ft. lbs. (39-49 Nm).
     
    Exhaust manifold heat shields. Tighten the bolts to 84-96 inch lbs. (9-11 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

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

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust front pipes
     
    Exhaust manifolds with catalytic converters attached. Loosen the nuts in the reverse of the torque sequence.
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold bolt torque sequence-3.3L engine

  1. Install or connect the following:

    Exhaust manifolds with catalytic converters attached. Tighten the nuts in sequence to 21-25 ft. lbs. (28-33 Nm).
     
    Exhaust front pipes. Tighten the bolts to 21-25 ft. lbs. (28-33 Nm).
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    EGR tube. Tighten the flange fittings to 29-36 ft. lbs. (39-49 Nm).
     
    Exhaust manifold heat shields. Tighten the bolts to 84-96 inch lbs. (9-11 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

 
label.common.footer.alt.autozoneLogo