1.Disconnect battery negative cable.
2.Raise the vehicle and support safely.
3.Remove the exhaust pipe to exhaust manifold nuts and separate exhaust pipe. Discard gasket.
5.Remove electric cooling fan assembly, if necessary.
6.If the oxygen sensor is located in the manifold, remove the sensor.
7.Disconnect necessary EGR components.
8.Remove outer exhaust manifold heat shield and engine hanger. Detach the electrical connector and remove the oxygen sensor.
9.Remove the exhaust manifold mounting bolts, the inner heat shield and the exhaust manifold.
10.Clean all gasket material from the mating surfaces and check the manifold for damage.
11.Using a new gasket, install the manifold. For 1.5L engines, tighten the nuts in a crisscross pattern to 13 ft. lbs. (18 Nm). For 1.8L engines, tighten the inner nuts in a crisscross pattern to 13 ft. lbs. (18 Nm) and tighten the two outer (larger) nuts to 22 ft. lbs. (30 Nm).
12.Install the heat shields.
13.Connect EGR components.
14.If removed, install the oxygen sensor.
15.Install the electric cooling fan assembly as required.
16.Install a new flange gasket and connect the exhaust pipe.
17.Connect the negative battery cable and check for exhaust leaks.
Thursday, July 8th, 2010 AT 8:44 PM