Exhaust Manifold Front Pipe Replacement RPO LD8

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

1. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
2. Remove the transaxle. Refer to Transmission Replacement .
3. Remove the front exhaust pipe to exhaust manifold bolts (2).




Important: The EGR valve inlet pipe incorporates a crush seal connection at the water pump housing. The EGR valve inlet pipe must be replaced if disconnected from the water pump housing.

4. Disconnect the EGR inlet pipe nut from the front exhaust manifold pipe.



5. Remove the front exhaust manifold pipe to lower crankcase bolt.
6. Remove the front exhaust manifold pipe to cylinder head stud.
7. Remove the front exhaust manifold pipe.
8. Remove the front exhaust manifold pipe seal from the left exhaust manifold and discard the seal.
9. Remove the exhaust manifold flange retainer.

1. Place the retainer and a NEW front exhaust manifold pipe seal over the left exhaust manifold.
2. Insert the front exhaust manifold pipe over the left exhaust manifold.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the front exhaust manifold pipe to cylinder head stud.

Tighten
Tighten the stud to 25 N·m (18 lb ft).

4. Install the front exhaust manifold pipe to lower crankcase bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).





Important: The EGR valve inlet pipe incorporates a crush seal connection at the water pump housing. The EGR valve inlet pipe must be replaced if disconnected from the water pump housing.

5. Connect the EGR inlet pipe nut to the front exhaust manifold pipe.

Tighten
Tighten the nut to 60 N·m (44 lb ft).




6. Install the front exhaust pipe to exhaust manifold bolts (2).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

7. Install the transaxle. Refer to Transmission Replacement .
8. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .