Contents: Models 1.5 l and 1.8 l ⤓ Engines 1.6 l and 2.0 l ⤓ 2.4L engines ⤓ Engines 3.0 l ⤓ 3.5L engines ⤓
Exhaust manifold installation details for 1.5L models
1 - Exhaust manifold cover A; 2 - Oxygen sensor (federal models 1992 and 1993); 3 - Power unit lifting eye; 4 - Exhaust manifold; 5 - Cover B of the exhaust manifold; 6 - Sealing gasket; 7 - Water tract hose; 8 - Water inlet pipe; 9 - Sealing ring; 10 - Water pump; 11 - Sealing gasket
Exhaust manifold installation details for 1.8L models
1 - Oxygen sensor (federal models 1992 and 1993); 2 - Cover A* of the exhaust manifold; 3 - Bracket B of the exhaust manifold (front-wheel drive models of 1992 (from November inclusive)*; 4 - Bracket A of the exhaust manifold (front-wheel drive models of 1992 (from November inclusive)*; 5 - Exhaust manifold bracket (front-wheel drive models produced in 1992 (up to and including October); 6 - Exhaust manifold*; 7 - Cover B of the exhaust manifold (federal models of 1992 and 1993); 8 - Sealing gasket
* Shape may vary depending on year of model release
Exhaust Manifold Installation Details for 2.0L SOHC Models
1 - Oil level dipstick; 2 - Guide tube of the measuring probe; 3 - Sealing ring; 4 - Heat shield; 5 - Power unit lifting eye; 6 - Exhaust manifold; 7 - Sealing gasket; 8 - Water inlet pipe; 9 - Sealing ring; 10 - Water pump; 11 - Sealing gasket
Exhaust Manifold Installation Details for 1.6L and 2.0L DOHC Non-Turbo Models
1 - Oil level dipstick; 2 - Guide tube of the measuring probe; 3 - Sealing ring; 4 - Heat shield A; 5 - Heat shield B; 6 - Power unit lifting eye; 7 - Exhaust manifold; 8 - Sealing gasket; 9 - Water inlet pipe; 10 - Sealing ring; 11 - Water pump; 12 - Sealing gasket
Exhaust Manifold Installation Details for 2.0L DOHC Turbocharged Models
1 - Oil level dipstick; 2 - Guide tube of the measuring probe; 3 - Sealing ring; 4 - Heat shield A; 5 - Heat shield B; 6 - Outlet pipe; 7 - Sealing gasket; 8 - Air outlet pipe; 9 - Sealing gasket; 10 - Water pipe B; 11 - Oil return pipe; 12 - Sealing gasket; 13 - Assembling the turbocharger; 14 - Sealing gasket; 15 - Ring; 16 - Oil pipeline; 17 - Water pipe; 18 - Turbocharger; 19 - Power unit lifting eye; 20 - Exhaust manifold; 21 - Sealing gasket; 22 - Water pipe; 23 - Water hose; 24 - Water hose; 25 - Water inlet pipe; 26 - Sealing ring; 27 - Water pump; 28 - Sealing gasket
Exhaust Manifold Installation Details for 3.0L SOHC Models
1 - Oil level dipstick; 2 - Guide tube of the measuring probe; 3 - Sealing ring; 4 - Heat shield; 5 - Right lifting eye of the power unit; 6 - Right exhaust manifold; 7 - Sealing gasket; 8 - Left heat shield (California models through 1993 and Federal models through 1994); 9 - Bracket; 10 - Left exhaust manifold (California models through 1993 and Federal models through 1994); 11 - Left exhaust manifold (California models since 1994 and Federal models since 1995); 12 - Sealing gasket; 13 - Water tract hose; 14 - Water tract hose; 15 - Water circuit bypass hose; 16 - Water inlet pipe B (models with manual transmission); 17 - Sealing ring (models with manual transmission); 18 - Water inlet pipe A (models with AT); 19 - Water inlet pipe (models with AT); 20 - Sealing ring; 21 - Water pump; 22 - Sealing gasket
Exhaust Manifold Installation Details for 3.0L DOHC Models
1 - Oil level dipstick; 2 - Guide tube of the measuring probe; 3 - Sealing ring; 4 - Right heat shield; 5 - Right lifting eye of the power unit; 6 - Right exhaust manifold; 7 - Sealing gasket; 8 - Left heat shield (Diamante - California models up to 1993, and federal models up to 1994, 3000GT - California models up to 1993); 9 - Left exhaust manifold; 10 - Left exhaust manifold (Diamante - California models from 1994, and federal models from 1995, 3000GT - California models through 1993); 11 - Sealing gasket; 12 - Sealing ring; 13 - Water inlet pipe; 14 - Sealing ring; 15 - Water pump; 16 - Sealing gasket
Exhaust Manifold Installation Details for 3.0L DOHC Models
Front row of cylinders:
1 - Heat shield; 2 - Exhaust manifold; 3 - Sealing gasket
Rear row of cylinders:
4 - Heat shield; 5 - EGR pipe; 6 - EGR pipe gasket; 7 - Exhaust manifold; 8 - Sealing gasket
Models 1.5 l and 1.8 l
Removal
1. The details of the exhaust manifold installation on 1.5L and 1.8L models are shown in the illustrations.
2. Disconnect the negative cable from the battery.
If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
3. Jack up the car and place it on supports.
4. Loosen the mounting nuts and separate the front exhaust pipe from the exhaust manifold. Remove the sealing gasket.
5. Lower the vehicle to the ground.
6. Remove the cooling fan assembly.
7. If the oxygen sensor is installed on the exhaust manifold, remove it.
8. Disconnect the appropriate exhaust gas recirculation (EGR) system components.
9. Remove the exhaust manifold outer heat shield and the powertrain lifting eye. Disconnect the electrical wiring from the oxygen sensor.
10. Remove the mounting bolts and remove the inner heat shield and manifold assembly.
Installation
1. Thoroughly clean the mating surfaces of the manifold and block, then wipe them with a rag soaked in acetone.
2. Place a new sealing gasket on the manifold. Install the manifold in its regular place and tighten the fasteners to the required force (for 1.5 l engines: 18 N·m, for 1.8 l engines: inner nuts - 18 N·m, two outer (large) - 30 N·m).
Tighten evenly, in a diagonal order.
3. Install heat shields.
4. Connect the EGR components.
5. If removed, reinstall the oxygen sensor.
6. Install the cooling fan assembly.
7. Connect the exhaust pipe to the exhaust manifold.
8. Connect the negative battery cable and check the exhaust system for signs of leaks.
Engines 1.6 l and 2.0 l
Removal
1. The details of the exhaust manifold installation on 1.6L and 2.0L models are shown in the illustrations.
2. Disconnect the negative cable from the battery.
If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
3. Jack up the car and place it on supports.
4. Loosen the mounting nuts and separate the front exhaust pipe from the exhaust manifold. Remove the sealing gasket.
5. Lower the vehicle to the ground.
6. On models equipped with air conditioning, remove the system fan assembly.
7. Using special tool MD998703 or its equivalent, disconnect and remove the oxygen sensor.
8. Remove the exhaust manifold outer heat shield and the powertrain lifting eye.
9. Remove the mounting bolts and remove the inner heat shield and manifold assembly from the engine.
Installation
1. Thoroughly clean the mating surfaces of the manifold and block, then wipe them with a rag soaked in acetone.
2. Place a new sealing gasket on the manifold. Install the manifold in its standard place and tighten the fasteners to the required torque (for 2.0 l SOHC engines: 15÷20 N·m, for 1.6 l and 2.0 l DOHC engines: 25÷30 N·m).
Tighten evenly, in a diagonal order.
3. Install the outer heat shield, screw in the mounting bolts and tighten them to the required torque (14 Nm).
4. If removed, reinstall the fan assembly.
5. Connect the exhaust manifold to the exhaust pipe (remember to replace the sealing gasket). Screw on the fastening nuts and tighten them to the required torque (40÷50 N·m).
6. Connect the negative battery cable and check the exhaust system for signs of leaks.
2.4L engines
Removal
1. Disconnect the negative cable from the battery.
If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
2. Jack up the car and place it on supports.
3. Loosen the mounting nuts and bolt of the support hanger, then separate the exhaust pipe from the exhaust manifold. Remove the sealing gasket.
4. Remove the exhaust manifold outer heat shield and the power unit lifting eye.
5. Loosen the mounting nuts and remove the exhaust manifold assembly from the engine.
Installation
1. Thoroughly clean the mating surfaces of the manifold and block, then wipe them with a rag soaked in acetone.
2. Place a new sealing gasket on the manifold. Install the manifold in its regular place and tighten the fastening nuts with the required force (25÷29 N·m).
Tighten the fasteners evenly, in a diagonal order.
3. Install the heat shields, screw in the mounting bolts and tighten them to the required torque (14 Nm).
4. Connect the exhaust pipe to the exhaust manifold (remember to replace the sealing gasket). Screw on the mounting nuts and tighten them to the required torque (44 N·m).
5. Connect the negative battery cable and check the exhaust system for signs of leaks.
Engines 3.0 l
Removal
1. The exhaust manifold installation details on 3.0L models are shown in the illustrations.
2. Disconnect the negative cable from the battery.
If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
3. Jack up the car and place it on supports.
4. Loosen the mounting nuts and separate the front exhaust pipe from the exhaust manifold.
5. Lower the vehicle to the ground.
6. To remove the front manifold, first remove the air conditioning fan assembly.
7. To remove the front manifold on DOHC engines, first remove the generator assembly with the support bracket.
8. On DOHC engines, remove the A/C compressor from its support bracket and, without disconnecting the refrigeration lines, set it aside.
9. To remove the front manifold, remove the muzzle oil dipstick and dismantle its guide tube.
10. To remove the front manifold on DOHC engines, remove the heat shield.
11. To remove the rear manifold, disconnect the EGR pipe.
12. To remove the rear manifold on SOHC engines, first remove the intake air duct plenum stand and turn the jet thrust bracket to the side.
13. Disconnect the electrical wiring and remove the oxygen sensor.
14. Remove the mounting bolts and the exhaust manifold assembly.
Installation
1. Thoroughly clean the mating surfaces of the manifold and block, then wipe them with a rag soaked in acetone.
2. Place a new sealing gasket on the manifold. Install the manifold in its original place and tighten the fastening nuts to the required torque (for SOHC engines: 30 N·m, for DOHC engines: 19 N·m).
Tighten the fasteners evenly, in a diagonal order.
3. Install heat shields.
4. If equipped, connect the EGR pipe, install the plenum stand and the reactive strut bracket.
5. Install the oxygen sensor.
6. Install the fan assembly, A/C compressor, dipstick guide tube and alternator assembly.
7. Connect the exhaust pipe to the exhaust manifold (remember to replace the sealing gasket).
8. Install the drive belt(s) and adjust its (their) tension.
9. Connect the negative battery cable and check the exhaust system for signs of leaks.
3.5L engines
Removal
1. Details of the exhaust manifold installation on 3.5L models are shown in the illustration.
2. Disconnect the negative cable from the battery.
If your car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
3. Jack up the car and place it on supports.
4. Loosen the mounting nuts and separate the front exhaust pipe from the exhaust manifold.
5. To remove the rear manifold, disconnect the EGR pipe.
6. Remove the mounting bolts and the exhaust manifold assembly.
Installation
1. Thoroughly clean the mating surfaces of the manifold and block, then wipe them with a rag soaked in acetone.
2. Place a new sealing gasket on the manifold. Install the manifold in its regular place and tighten the fastening nuts with the required force (30 N·m).
Tighten the fasteners evenly, in a diagonal order.
3. Install the heat shield(s).
4. When installing the rear manifold, connect the EGR pipe.
5. When installing the front manifold, reinstall the cooling fan assembly with the radiator.
6. When installing the front manifold, install the generator in place.
7. Install the drive belt(s) and adjust its (their) tension.
8. Jack up the car and place it on supports.
9. Connect the exhaust pipe/catalytic converter assembly to the exhaust manifold (remember to replace the sealing gasket).
10. Lower the car to the ground.
11. Connect the negative battery cable and check the exhaust system for signs of leaks.