Exhaust manifold

Exhaust manifold was cracked long time ago, once repaired using high temp exhaust putty.

It was temporary fix and I ordered new one from 1Aauto, part# 1AEEM00146. Arrived with felpro manifold and flange gaskets.

note down  and mark all electrical, vacuum connections and start.

1. Anyway, disconnect battery

2. Disconnect throttle cable, transmission pressure cable and cruise control cable (if equipped)

3. Remove air filter box

4. Disconnect vacuum hoses (MAP, brake, regulator, CCV/PCV etc)

5. Disconnect electrical connections (water temp sensor, injectors etc)
6. Loosen belt and remove power steering pump
7. Remove upper bolt of PS pump bracket and loosen lower one

8. Loosen bolts and nuts of intake/exhaust manifold (they are 15mm), remove top 4 and bottom 4 bolts. Leave 2 bolts and 1 stud of exhaust manifold.

9. Pull out intake manifold and be prepared, there would be sooo dirty.

 

Flange nut was really hard to open, brake fluid helps a lot. 

Poor old boy, you served well on those years...

lots of build-ups here:

and there:

Inserted cloth in holes and soaked with carb cleaner frequently and remove all residues of old gasket.

Lots of carb cleaner and some beer required to fully remove all dirt.

nice and clean

new manifold with flange gasket


test fit

go ahead with installation ("installation is reverse of removal")

Connect everything and check again

Reset ECU/PCM and start engine.

lots of smoke from new exhaust, don't worry. Like all new parts, exhaust manifold arrive with oil and we have to burn them all.