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Exhaust Manifold

REMOVAL & INSTALLATION

3000GT
NON-TURBOCHARGED ENGINES
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    To install:

  3. Clean all gasket material from the mating surfaces.
  4. Install or connect the following:
TURBOCHARGED ENGINES
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Disconnect the negative battery cable.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:

    NOTE: The cone disc springs are installed at all lower mounting points.

    To install:

  5. Clean all gasket material from the mating surfaces.
  6. Install new gaskets and install the manifold. Be sure all cone disc springs are in their original locations with the grooved side facing the nut. Tighten the manifold nuts using the following procedure:
    1. Tighten all but the outer 2 nuts to 22 ft. lbs. (30 Nm).
    2. Tighten the outer 2 nuts to 34–38 ft. lbs. (47–53 Nm).
    3. Loosen the outer 2 nuts, then tighten them to 22 ft. lbs. (30 Nm).
  7. Install or connect the following:
  8. Fill the cooling system.
  9. Connect the negative battery cable and check for exhaust leaks.
Diamante
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:
  3. For the DOHC engine, remove the following:
  4. If removing the front manifold, remove the oil dipstick and tube from the engine.
  5. If removing the rear manifold, disconnect the EGR tube.
  6. For the SOHC engine, if removing the rear manifold, remove the intake plenum stay and the roll stopper bracket.
  7. Remove or disconnect the following:

    To install:

  8. Clean all gasket material from the mating surfaces.
  9. Install or connect the following:
Eclipse

Fig. 1: Exhaust manifold and related parts — Eclipse 2.0L (4G63) engine

2.0L (4G63) ENGINE

CAUTION
The air bag system must be disarmed before removing the exhaust manifold or turbocharger.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Disconnect the negative battery cable.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:

    To install:

  5. Use a new gasket and install the exhaust manifold.
  6. Use a new gasket and install the turbo to the exhaust manifold. Be sure the coned disc spring and the washers are installed in their original positions. Torque the bolts and nuts to specification, loosen them and tighten them again.

    Fig. 2: Install the groove of the cone-shaped disc spring toward the flange bolt or nut — Eclipse 2.0L (4G63) engine

  7. Use a new gasket and connect the exhaust pipe to the turbo.
  8. Using new gaskets, install the oil return pipe.
  9. Install or connect the following:
2.0L (420A) ENGINE

Fig. 3: Exploded view of the exhaust manifold and related components — 2.0L (420A) engine

CAUTION
The air bag system must be disarmed before removing the exhaust manifold.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Disconnect the negative battery cable.
  3. Drain the engine coolant.
  4. Remove or disconnect the following:

    To install:

  5. Use a new gasket and install the exhaust manifold. Torque the nuts and bolts to 17 ft. lbs. (23 Nm).
  6. Install the lower heat shield.
  7. Use a new gasket and connect the front exhaust pipe to the manifold.
  8. On vehicles with manual transaxles, connect the pulsed secondary air injection valve to the exhaust pipe.
  9. Install or connect the following:
  10. Attach the engine wiring harness to the rear of the engine.
  11. Install or connect the following:
  12. Refill the engine with coolant, start the engine and check for leaks.
2.4L (4G64) ENGINE

CAUTION
The air bag system must be disarmed before removing the exhaust manifold or turbocharger.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    To install:

  3. Install a new exhaust manifold gasket to the cylinder head and install the exhaust manifold. Torque the mounting nuts to 21 ft. lbs. (29 Nm).
  4. Replace the heat shield and tighten the bolts to 10 ft. lbs. (13 Nm).
  5. Install a new gasket between the exhaust manifold and the front exhaust pipe and reconnect the pipe. Torque the nuts to 32 ft. lbs. (34 Nm).
  6. Reconnect the negative battery cable, start the engine and check for any exhaust leaks.

    Fig. 4: Exploded view of the exhaust manifold mounting — Eclipse 2.4L (4G64) engine shown, Galant similar

Galant
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    To install:

  3. Clean all gasket material from the mating surfaces.
  4. Install a new gasket and install the manifold. Tighten the nuts to in a crisscross pattern to 18–21 ft. lbs. (25–29 Nm).
  5. Install the heat shields and tighten the mounting bolts to 10 ft. lbs. (14 Nm).
  6. Install a new flange gasket and connect the exhaust pipe. Tighten the mounting nuts to 32 ft. lbs. (44 Nm).
  7. Connect the negative battery cable and check for exhaust leaks.
Mirage
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:

    To install:

  3. Clean all gasket material from the mating surfaces.
  4. Using a new gasket and install the manifold. For 1.5L engines, tighten the nuts on a crisscross patter to 13 ft. lbs. (18 Nm). For 1.8L engines, tighten the inner nuts to in a crisscross pattern to 13 ft. lbs. (18 Nm) and tighten the 2 outer (larger) nuts to 22 ft. lbs. (30 Nm).
  5. Install or connect the following:

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