Contents: Front section of the exhaust manifold ↳ Removal ↳ Installation ↳ Rear section of the exhaust manifold ↳ Removal ↳ Installation ↳
Warning: This procedure must be performed when the engine is completely cool.
Front section of the exhaust manifold
Removal
1. Disconnect the negative battery cable (Chapter 5, paragraph 1).
2. Disconnect the wiring from the oxygen sensor mounted on the exhaust manifold.
3. Unscrew the connecting nuts and remove the EGR system connecting pipe from the intake and exhaust manifolds.
4. If necessary, drain the cooling system (Chapter 1) to improve access and remove the lower radiator hose.
5. Remove the exhaust manifold bolts from the exhaust pipe.
6. Unscrew the nuts and remove the manifold and gasket (see Fig. 7.6, a, b).
7. If necessary, unscrew the oxygen sensor from the manifold (Chapter 4B).
8. Clean the mating surfaces of the manifold and cylinder head.
Installation
9. If the oxygen sensor was removed, install and secure it (Chapter 4B).
10. Always install a new gasket on the cylinder head studs.
11. Install the manifold section and tighten the nuts sequentially to the specified torque.
13. If the radiator hose was removed, reinstall it and tighten its clamp. Fill the cooling system (Chapter 1).
14. Install the EGR pipe connecting the intake and exhaust manifolds and tighten the nuts to the specified torque.
15. Connect the wiring to the oxygen sensor.
16. Connect the negative battery cable (Chapter 5, Section 1). Note: To restore the engine management system settings due to the battery being disconnected, a mileage of approximately 16 km is required. In this case, the engine may not operate normally.
Rear section of the exhaust manifold
Removal
17. Disconnect the negative battery cable (Chapter 5, paragraph 1).
18. Apply the parking brake. Raise the front end and place it on supports. Remove the right front wheel.
19. Remove the generator (Chapter 5A). Unscrew the bolts and remove the generator bracket from the cylinder block.
20. Remove the catalytic converter (Chapter 4A) from the exhaust system. Disconnect the exhaust inlet pipe from the exhaust manifold.
21. Remove the oxygen sensor from the manifold (chapter 4B).
22. Remove the right drive shaft bearing support bolts from the cylinder block.
23. Unscrew the fitting nut and separate the EGR system connecting pipe from the exhaust manifold.
24. Unscrew the nuts and remove the manifold and gasket (see Fig. 7.24, a, b).
25. Clean the mating surfaces of the manifold and cylinder head.
Installation
26. Always install a new gasket on the cylinder head studs.
27. Install the manifold section and tighten the nuts sequentially to the specified torque.
28. Connect the EGR system connecting pipe and tighten the fitting nut.
29. Install the right input shaft bearing support to the cylinder block and tighten the bolts to the specified torque.
30. Install the exhaust pipe and catalytic converter. (Chapter 4A).
32. Install the generator bracket, tighten its bolts. Then install the generator (Chapter 5A).
33. Install the right front wheel and lower the vehicle to the ground.
34. Connect the negative battery cable (Chapter 5, Section 1).
Note: To restore the engine management system settings due to the battery being disconnected, a mileage of about 16 km is required. In this case, the engine may not operate normally.
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