Removal procedure
1. Disconnect the negative battery cable.
2. Remove the front exhaust pipe. See Part 1G3, Exhaust System - HFV6 3.2L.
3. Remove the auxiliary catalytic converter. See Part 1G3, Exhaust System - HFV6 3.2L.
4. Bank 1 exhaust manifold: Remove transfer case. See Part 5D. "Transfer case".
5. Bank 1 exhaust manifold: remove the transaxle rear mount assembly. See «Rear Suspension Gearbox with Final Drive Assembly» in this section.
6. Disconnect the upstream oxygen sensor connector.
7. Remove three bolts (1) fastening of the outer heat-insulating shield (2) to the exhaust manifold.
8. Gradually loosen the seven exhaust manifold mounting bolts from the center to the peripheral bolts, and then remove the bolts.
9. Remove and discard the gasket between the exhaust manifold and cylinder head.
10. Remove the three bolts securing the inner heat shield to the exhaust manifold, if required.
Clear
1. Thoroughly clean the exhaust manifold using one of the common non-corrosive cleaning solvents and a soft bristled brush.
2. Dry the exhaust manifold with compressed air.
Inspection
1. Check exhaust manifold (1), by checking for the following faults:
- Damage to the threaded holes intended for fastening the heat-insulating shields.
- Damage to the holes for attaching the exhaust manifold.
- Damage to the threads of the exhaust manifold to the exhaust pipe flange studs.
- Damage to surfaces sealed with gaskets.
- Using a ruler (2) and probes (3), check the joint surface of the exhaust manifold with the cylinder head for deformation, which should not exceed 0.25 mm.
Note: If the surface is not flat, the exhaust manifold is deformed and must be replaced.
Installation procedure
1. Install the exhaust manifold inner heat shield, if required.
Tighten
Tighten the exhaust manifold inner heat shield bolts to 10 Nm (89 lb-ft).
2. Place a new exhaust manifold gasket on the manifold.
3. Lubricate the threads of the exhaust manifold mounting bolts with Loctite 272 thread sealant (or equivalent).
Note: When tightening the exhaust manifold-to-cylinder head bolts, start with the center bolts and then alternately move to the bolts located on opposite sides.
4. Install the exhaust manifold and mounting bolts.
Tighten
Tighten the exhaust manifold-to-cylinder head bolts to 20 Nm (15 lb-ft).
5. Install the exhaust manifold heat shield.
Tighten
Tighten the exhaust manifold outer heat shield bolts to 10 Nm (89 lb-ft).
6. Install previously removed outer parts.
