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 assembly. Refer to Transmission Replacement in Automatic Transaxle-4T80-E.



3. Remove the 2 bolts attaching the left exhaust manifold to the front exhaust manifold pipe.



4. Remove the bolt (1) securing the front exhaust manifold pipe (2) to the crankcase.
5. Remove the nut securing the coil cassette ground wire to the cylinder head.
6. Remove the bolt (3) securing the front exhaust manifold pipe (2) to the cylinder head.

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

7. Disconnect the EGR inlet pipe nut from the front exhaust manifold pipe (2).
8. Remove the front exhaust manifold pipe (2).
9. Remove the front exhaust manifold pipe seal from the left exhaust manifold. Do not reuse the seal.
10. Remove the exhaust manifold flange retainer.

Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

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

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the bolts (1, 3) securing the front exhaust manifold pipe (2) to the engine.

Tighten
Tighten the front exhaust manifold pipe support bolts to 25 N·m (18 lb ft).

4. Install the nut securing the coil cassette ground wire to the cylinder head.

Tighten
Tighten the coil cassette ground wire nut to 17 N·m (13 lb ft).




5. Install the 2 bolts securing the front exhaust manifold pipe to the left exhaust manifold.

Tighten
Tighten the front exhaust manifold pipe bolts to 25 N·m (18 lb ft).

6. Hand start the EGR inlet pipe nut to the front exhaust manifold pipe to prevent cross threading.

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

7. Install the transaxle assembly. Refer to Transmission Replacement in Automatic Transaxle-4T80-E.
8. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .