Exhaust Manifold Replacement - Right Side LX5

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. Disconnect the cruise control cable (2) from the throttle body lever and bracket and position aside.
2. Disconnect the accelerator cable from the throttle body lever and bracket and position aside.
3. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5 L.
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.5 L.



5. Remove the fasteners attaching the accelerator control cable bracket to the throttle body.
6. Remove the accelerator control cable bracket.
7. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
8. Remove the transaxle filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement in Automatic Transaxle - 4T65-E.
9. Set the park brake and chock the wheels.



10. Fully lift the retainer from the transaxle range selector cable mechanism.



11. Disconnect the transaxle range selector cable terminal from the transaxle manual shift lever pin.
12. Press the locking tabs inward in order to release the transaxle range selector cable from the bracket.
13. Remove the transaxle range selector cable and position aside.



14. Remove the bolt (1) connecting the ground lead to the top of the transaxle.



15. Disconnect the C101 (2) at the left strut tower.



16. Disconnect the left wheel speed sensor connector (3).
17. Remove the left wheel speed sensor lead (1) from the retaining brackets (2).



18. Disconnect the C100 (2) at the top of the transaxle.
19. Disconnect the harness (3) from the harness clip (1) and position the harness (3) aside.



20. Remove the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.
21. Position the exhaust manifold heat shield aside in order to remove the right exhaust manifold crossover bolts.
22. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



23. Remove the two bolts attaching the left exhaust manifold to the right exhaust manifold crossover.
24. Remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement .



25. Remove the right exhaust manifold studs.
26. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.5 L.



27. Disconnect the EGR inlet pipe from the right exhaust manifold.
28. Remove the right exhaust manifold retaining bolts.
29. Lower the vehicle.
30. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
31. Remove the exhaust manifold crossover seal from the left exhaust manifold. Do not reuse the seal.
32. Clean and inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection - Right Side in Engine Mechanical-3.5L Unit Repair.

1. Place a NEW exhaust manifold crossover seal over the left exhaust manifold.



2. Install the right exhaust manifold to the engine in the following order:

2.1.	Align the exhaust manifold to the cylinder head.

2.2.	Place the crossover portion of the exhaust manifold around the left exhaust manifold.

2.3.	Hold the right exhaust manifold to the right cylinder head using a retaining bolt.

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Grasp the right exhaust manifold and remove the retaining bolt.
5. Place a NEW exhaust manifold gasket between the right exhaust manifold and the right cylinder head.

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.

6. Install the right exhaust manifold bolts.

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

7. Connect the EGR inlet pipe to the right exhaust manifold.

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




8. Install the right exhaust manifold studs.

Tighten
Tighten the exhaust manifold studs to 9 N·m (80 lb in).

9. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.5 L.
10. Install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement .



11. Install the two bolts attaching the left exhaust manifold to the right exhaust manifold crossover.

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

12. Lower the vehicle.



13. Position the exhaust manifold heat shield to the left exhaust manifold.
14. Install the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.

Tighten
Tighten the exhaust manifold heat shield bolts to 9 N·m (80 lb in).




15. Connect the harness (3) to the harness clip (1).
16. Connect the C100 (2) to the transaxle.



17. Connect the left wheel speed sensor connector (3) to the left wheel speed sensor.
18. Attach the left wheel speed sensor lead (1) to the retaining brackets (2).



19. Connect the C101 (2) at the left strut tower.



20. Install the bolt (1) connecting the ground lead to the top of the transaxle.

Tighten
Tighten the ground lead bolt to 17 N·m (13 lb ft).




21. Insert the transaxle range selector cable into the bracket.
22. Connect the transaxle range selector cable terminal to the transaxle manual shift lever pin.



23. Install the retainer to the transaxle range selector cable mechanism.
24. Adjust the transaxle range selector cable. Refer to Range Selector Lever Cable Adjustment in Automatic Transaxle - 4T65-E.
25. Install the transaxle filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement in Automatic Transaxle - 4T65-E.
26. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.



27. Position the accelerator control cable bracket to the throttle body.
28. Install the fasteners attaching the accelerator control cable bracket to the throttle body.

Tighten

•	Tighten the accelerator control cable bracket bolt to 13 N·m (115 lb in).

•	Tighten the accelerator control cable bracket nuts to 10 N·m (89 lb in).

29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.5 L.
30. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5 L.




Important: The throttle should operate freely without binding between full closed and wide open throttle.

31. Connect the accelerator cable to the throttle body lever and bracket.
32. Connect the cruise control cable (2) to the throttle body lever and bracket.

Exhaust Manifold Replacement - Right Side L47

Tools Required

J 42640 Steering Column Lock Pin

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. Disconnect the heated oxygen sensor at the sensor pigtail.




Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

2. Lock the steering column by installing the J 42640 into the underside of the steering column.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .



5. Remove the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).
6. Remove the secondary AIR tube (1) and the gasket from the exhaust manifold (3). Do not reuse the gasket.



7. Disconnect the post heated oxygen sensor wiring harness retainer from the power steering gear heat shield.
8. Remove the two bolts securing the heat shield.
9. Remove the heat shield from the power steering gear.



10. Remove the rearward nut (3) securing the vehicle speed sensor heat shield (1).
11. Loosen the forward nut (2) in order to remove the heat shield (1).
12. Remove the heat shield (1) from the transaxle.




Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

13. Remove the intermediate shaft pinch bolt.
14. Disconnect the intermediate shaft from the steering gear.



15. Remove the nut securing the right engine mount to the right engine mount bracket.



16. Remove the nut securing the left transaxle mount to the left transaxle mount bracket.



17. Support the rear of the engine frame with a tall screw jack.
18. Remove the four rearward engine frame-to-body bolts.
19. Lower the screw jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.
20. Remove the heated oxygen sensor if replacement is necessary. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 in Engine Controls - 4.0 L.



21. Remove the right exhaust manifold retaining nuts.
22. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
23. Clean and inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection - Right Side in Engine Mechanical-4.0L Unit Repair.

1. Place a NEW exhaust manifold gasket over the cylinder head studs.
2. Position the right exhaust manifold to the right cylinder head.

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 right exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 25 N·m (18 lb ft).

4. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 in Engine Controls - 4.0 L.



5. Raise the engine cradle into position.
6. Install the four rearward engine frame-to-body bolts.

Tighten
Tighten the engine frame bolts to 191 N·m (141 lb ft).

7. Remove the screw jack.



8. Install the nut securing the left transaxle mount to the left transaxle mount bracket.

Tighten
Tighten the transaxle mount nut to 80 N·m (59 lb ft).




9. Install the nut securing the right engine mount to the right engine mount bracket.

Tighten
Tighten the engine mount nut to 80 N·m (59 lb ft).





Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

10. Connect the intermediate shaft to the steering gear.
11. Install the intermediate shaft pinch bolt.

Tighten
Tighten the intermediate shaft pinch bolt to 45 N·m (33 lb ft).




12. Position the vehicle speed sensor heat shield (1) to the studs on transaxle.
13. Install the retaining nuts (2, 3) securing the vehicle speed sensor heat shield to the transaxle.

Tighten
Tighten the vehicle speed sensor heat shield nuts to 50 N·m (37 lb ft).




14. Position the power steering gear heat shield to the power steering gear.
15. Install the two bolts securing the heat shield.

Tighten
Tighten the power steering gear heat shield bolts to 9 N·m (79 lb in).

16. Connect the post heated oxygen sensor wiring harness retainer to the heat shield.



17. Install the new gasket to the secondary AIR tube (1).
18. Install the two nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).

Tighten
Tighten the secondary AIR tube nuts to 12 N·m (106 lb in).

19. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
20. Lower the vehicle.



21. Remove the J 42640 from the steering column.
22. Connect the heated oxygen sensor at the sensor pigtail.