Before working on the exhaust system, make sure the engine is completely cool.
If your vehicle's radio is equipped with an anti-theft system, make sure you enter the correct code before disconnecting the battery.
If the instrument cluster displays the wrong language after connecting the battery, refer to Section Anti-theft audio system and instrument cluster language, which describes the procedure for installing the required language.
1. Disconnect the negative battery cable.
2. On models where the air cleaner is located on the same side of the engine as the exhaust manifold, remove the air cleaner housing and/or air flow meter assembly to provide sufficient room to work (see chapter Power supply system, if necessary).
For ease of operation, also remove the windshield washer reservoir from the right side of the engine compartment.
3. Disconnect the high voltage wires and move the spark plug wiring aside (see chapter Routine car maintenance).
4. Mark and then disconnect all wires, hoses, fittings, etc. that interfere with the work. Do not forget to disconnect the oxygen sensor where provided.
5. Jack up the vehicle and secure it on axle stands. Working underneath the vehicle, disconnect the exhaust pipe from the manifold. To make the job easier, use penetrating oil to lubricate the fasteners.
6. Remove the axle supports and lower the car. Moving from the ends of the manifold to its center, gradually loosen the mounting nuts so that they can be removed. Here again, penetrating oil can help.
7. Pull the manifold off the head, then remove the old gaskets.
Be extremely careful not to damage the oxygen sensor where provided.
8. Clean the mating surfaces of the head and manifold and make sure that the threads on the exhaust manifold valve clearance adjusting screws are not damaged.
9. Check the manifold for corrosion, deformation, cracks or other damage. Repair or replace the manifold if necessary.
10. When installing the manifold, use new gaskets. Tighten the manifold-to-head mounting nuts gradually, starting from the center and moving toward the edges, achieving the required force. Tighten the intake pipe mounting nuts to the manifold as well.
11. Perform the rest of the installation procedure in the reverse order of removal.
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