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Exhaust Manifold: Removal

  1. Release fuel pressure and disconnect fuel lines. See, in this article, FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS .
  2. Drain cooling system. Remove air intake tubing and upper radiator hose. Discharge A/C system. Disconnect outlet refrigerant line from compressor using Spring Lock Coupling Remover (T81P-19623-G1 or G2). Plug line opening.
  3. Remove outlet refrigerant line-to-right coil bracket bolt. Remove 42-pin connector from retaining bracket on vacuum booster. Disconnect 42-pin connector and transmission harness connector. See Figure.
  4. Remove dipstick tube-to-manifold retaining bolt from left manifold. Disconnect throttle valve cable from throttle body. Remove heater outlet hose.
  5. Disconnect ground strap from right cylinder head. Remove upper stud. Loosen heater outlet hose-to-right cylinder head lower bolt, and position out of the way.
  6. Remove blower motor resistor from housing on firewall. Remove right engine mount-to-lower engine bracket. Disconnect vacuum hoses from EGR valve and EGR tube. Remove EGR valve-to-intake manifold bolts.
  7. Disconnect both oxygen sensor connectors. Raise and support vehicle. Remove engine mount through bolts. There are 2 through bolts on left mount, and one bolt on right mount.
  8. Disconnect EGR tube from right exhaust manifold. Remove EGR valve and tube. Disconnect exhaust pipes from exhaust manifolds. Support exhaust pipes from crossmember using wire.
  9. Using floor jack and wooden block, raise engine approximately 4" with jack under oil pan.
  10. Remove retaining bolts and remove exhaust manifold. On left manifold, it will be necessary to remove engine mount before removing retaining bolts.
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