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How to install new exhaust manifold gaskets? - 850 Volvo Cars & Trucks

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You dont say what car it is all are similar apply penetrating oil to retaining nuts remove nuts pull back manifold remove old gasket clean gasket faces on manifold and cylinder head fit new gasket and reassemble if car is a volvo the manifold can crack so check this first

Posted on Jan 13, 2010

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Had 4 exhaust gaskets replaced over two year period now I have the same problem again


Hi Don. Is a shop doing the gasket replacement or was it a D.I.Y. thing? I ask because the problem may very well be a warped/cracked exhaust manifold, or worse a cylinder head issue. If your doing this yourself, perhaps remove the exhaust manifold and take it to a shop to be checked for warpage or cracks, and simply repace it (along with a new gasket of course) if yours is found to be faulty. Also, use new hardware ( studs/bolts) to install the manifold and torque to proper torque specs. Proper torque is important.

Feb 06, 2013 | 1987 Toyota Pickup

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Installing exhaust manifold


when installing exhaust manifold. The exhaust manifold gaskets have a metal side and a fiber side. Place the metal side towards the cylinder head. Sometimes the #1 & #2 exhaust gaskets need to be trimmed a tad so that the intake gasket will seat properly. Did it on both engines I've built.

on May 19, 2008 | 1986 Audi GT

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What is the torque setting for 1999 ford 182 exaust manifold


Check this for 1996-1999 FORD 3.0L (182) V6 DOHC...
- Install the exhaust manifold with a new exhaust manifold gasket.
- Install the exhaust manifold retaining studs and tighten to 13-16 ft. lbs. (18-22 Nm) in the sequence illustrated.
Raise and safely support the vehicle.
Position the Y-pipe assembly using a new flange gasket and install all the retaining nuts and bolts loosely.
Starting at the front of the system tighten the Y-pipe to exhaust manifold nuts to 26-34 ft. lbs. (34-46 Nm).

- Tighten the converter to transaxle nut and bolt to 30 ft. lbs. (40.3 Nm). Tighten the converter outlet bolts to 26-34 ft. lbs. (34-46 Nm).

zjlimited_1988.jpg

Fig. Right side exhaust manifold mounting bolt tightening sequence-3.0L DOHC engine (click image for zoom)


zjlimited_1989.jpg

Fig. Left side exhaust manifold mounting bolt tightening sequence-3.0L DOHC engine (click over image for zoom)

Hope this helps (remember to rating this answer).

Oct 06, 2011 | 1999 Ford Taurus

1 Answer

Where are the four O2 sensors on a 2003 Montero Sport? Is $300 reasonable to replace the two upstream sensors?


According to the service literature I read, the 2003 Montero Sport with the 3.0 or 3.5 L engine does not have O2 sensors listed even in the maintenance schedule. The 2.4 L engine has it on the exhaust manifold though.
---
However, the following lists the par, though for before or after the catalytic converter:

http://www.partstrain.com/store/index.php?VN=4294967180+4294966587+4294964143+&Nr=AND(universal:0)&N=0&Ntt=Oxygen%20Sensor

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I think that $250 to $300 is reasonable if the Oxygen sensors are stuck in there with rust and the threads are preserved by the technician. Oxygen Sensor replacement can be tricky.
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Good luck on this repair.

Exhaust Manifold

REMOVAL & INSTALLATION

2.4L Engine


  1. Remove or disconnect the following:

    • Negative battery cable

    CAUTION
    Wait at least 90 seconds after the negative
    battery cable is disconnected to prevent possible deployment of the air bag.


  2. Heat cowl from the exhaust manifold
  3. Aspirator valve assembly, if equipped
  4. Oil dipstick and guide
  5. Oxygen (O2S) sensor connector and ground cable, if equipped
  6. Exhaust pipe from the manifold
  7. Exhaust manifold and gasket from the engine
    To install:

  8. Install or connect the following:

    • Exhaust manifold. Torque the M8 mounting nuts to 22 ft. lbs. (29 Nm) and the
      M10 mounting bolts 36 ft. lbs. (49 Nm). starting from the middle and working
      outward.
    • O2S sensor connector and ground cable, if equipped
    • Exhaust pipe to the manifold. Torque the nuts to 35ft. (49 Nm).
    • Aspirator valve assembly, if removed
    • Heat cowl to the exhaust manifold. Torque the bolts to 117 inch lbs. (13
      Nm).
    • Negative battery cable

  9. Start the engine and check for exhaust leaks.


3.0L and 3.5L Engines


  1. Remove or disconnect the following:

    • Negative battery cable
    • Exhaust pipe from the exhaust manifolds
    • Oil dipstick, guide and O-ring
    • Heat shields
    • Exhaust manifolds

  2. Clean the gasket mounting surfaces. Inspect the manifolds for cracks,
    flatness and/or damage.
    To install:

  3. Install or connect the following:

    • New gasket and exhaust manifold. Torque the nuts to 33 ft. lbs. (44 Nm) on
      3.0L engines and 22 ft. lbs. (29 Nm) on 3.5L engines.
    • Heat shield, Torque the bolts to 10 ft. lbs. (14 Nm).
    • Exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).
    • Oil dipstick, guide and new O-ring
    • Negative battery cable

  4. Start the engine and check for exhaust leaks.


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Oct 07, 2010 | 2003 Mitsubishi Montero Sport

1 Answer

Where are the exhaust system bolts located?


Removal & Installation 2.2L Engine To Remove:
  1. Remove or disconnect the following:
    • Negative battery cable.
    • Heat shield.
    • Oxygen sensor.
  2. Raise and safely support the vehicle.
  3. Remove exhaust pipe from the exhaust manifold.
  4. Lower the vehicle.
  5. Remove the exhaust manifold mounting nuts from the cylinder head. chevy_cav_02-04_exmanifold.gif

  6. Remove the exhaust manifold.
  7. Clean the mating surfaces.
  8. Check for cracks, broken flanges and gasket surface damage.
  9. Use a straight edge and a feeler gauge. If the flanges or the mating surfaces do not align, the manifold is warped and should be replaced.
To Install:
NOTE: The manufacturer recommends using new exhaust system nuts.
  1. Install the manifold gasket.
  2. Position the exhaust manifold to the cylinder head. Exhaust manifold 2.2L 87953055.gif

  3. Install the new exhaust manifold nuts. Tighten the nuts starting from the center and working toward the ends to 110 in lbs (12.5 Nm).
  4. Raise and safely support the vehicle.
  5. Install the exhaust pipe to the manifold using a new flex coupler gasket.
  6. Install new exhaust flange mounting nuts.
    • Tighten to 33 ft lbs (45 Nm).
  7. Lower the vehicle.
  8. Install the oxygen sensor.
  9. Install the heat shield.
  10. Connect the negative battery cable.
2.4L Engine To Remove:
  1. Disconnect the negative battery cable
  2. Disconnect the Oxygen (O2) sensor electrical connector.
  3. Remove the (O2) sensor.
  4. Raise and safely support the vehicle. Exhaust brace 2.4L 87953053.gif

  5. Remove the exhaust manifold brace-to-manifold bolt and the oil pan nuts, if necessary. Exhaust heat shield 2.4L 87953051.gif

  6. Remove the upper heat shield. NOTE: Do NOT bend the exhaust flex decoupler more than necessary to remove it. Excessive movement will damage the flex decoupler
    Exhaust flex decoupler 87953056.gif

  7. Remove the manifold-to-exhaust flex decoupler fasteners.
  8. Remove the exhaust pipe.
  9. Carefully lower the vehicle.
  10. Remove the exhaust manifold-to-cylinder head mounting nuts/bolts. Remove the exhaust manifold.
  11. Discard the gaskets and/or seals. Clean the mating surfaces.
To Install:
Exhaust manifold 2.4L 87953055.gif

  1. Install new exhaust manifold gaskets. Position the exhaust manifold on the cylinder head. Tighten the mounting bolts in sequence to 110 in lbs (12.5 Nm).
  2. Raise and safely support the vehicle.
  3. Install the exhaust manifold heat shield. Tighten the mounting bolts to 10 ft. lbs (14 Nm).
  4. Install the exhaust manifold brace-to-manifold bolt and the oil pan nuts. Tighten the mounting bolts to 41 ft lbs (56 Nm) and the nuts to 18 ft lbs (24 Nm).
  5. Position the exhaust pipe to the manifold. Install the manifold-to-flex decoupler mounting bolts. Tighten to 26 ft lbs (35 Nm).
  6. Lower the vehicle.
  7. Coat the threads with a suitable anti-seize compound and install the O2 sensor.
  8. Connect the O2 sensor electrical connector.
  9. Connect the battery ground cable and check for leaks.
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Sep 02, 2010 | 2000 Oldsmobile Alero

1 Answer

I just bought a 1985 F250 2x4 6.2Liter. I notice some oil leaking out of the exhaust manifold and see that its burning up oil quickly. Will a new gasket fix this? How reliable is the oil guadge on the dash...


The guage is pretty reliable.

The leak isnt from your exhaust manifold, its coming from the valve cover gasket above it, and yes a new gasket will fix it if installed properly.

Nov 16, 2009 | 1985 Ford F 250

1 Answer

EGR VALVE 1999 MERCURY COUGER


SECTION 303-08: Engine Emission Control 1999 Cougar Workshop Manual REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Valve Removal
  1. Remove the air cleaner outlet tube.
    1. Disconnect the intake air bypass hose.
    1. Disconnect the positive crankcase ventilation hoses.
    1. Remove the air cleaner outlet tube.
  1. Disconnect the tube from the exhaust gas recirculation valve.
  1. Remove the exhaust gas recirculation valve.
    • Disconnect the vacuum hose.
Installation
  1. sxu~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: When cleaning the gasket faces, do not allow debris to enter the intake manifold or exhaust gas recirculation valve.
    Clean the gasket faces of the intake manifold and exhaust gas recirculation valve.
  1. Install a new exhaust gas recirculation valve gasket.
  1. Position the EGR valve and install the bolts.
    • Install the vacuum hose.
  1. Connect the EGR tube.
  1. Install the idle air control valve. For additional information, refer to Section 303-14A . For additional information, refer to Section 303-14B .

Sep 15, 2009 | 1999 Mercury Cougar

1 Answer

How do I replace the oil pan gasket on a 2001 GMC Yukon XL?


Changing the oil pan gasket on a GMC Yukon XL is realtively simple, but does require removal of the exhaust pipe. You will need a new oil pan gasket and a new exhaust pipe flange gasket.
Put the car on ramps or jacks to access the undercarriage.
Remove the exhaust pipe by removing the 3 nuts holding the exhaust pipe flange to the exhaust manifold. These nuts often rust and prior application of penetrating oil may be required to remove them without damage. Once the pipe is unbolted, work the exhaust system loose from the hanging brackets. In most cases the entire system does not have to be removed since there is enough room to remove the pan with only the front hangers removed.
Drain the oil from the engine
Remove the 10 mm bolts holding the pan to the block.
Remove the old gasket material and scrape any remaining gasket from the block and pan.
Install the new gasket. Forma-Gasket or a similar product may be used in small quantities to "glue" the new gasket in place and prevent shifting while the pan is reattached to the block.
Reinsall the 10 mm bolts in a cross pattern to ensure the gasket is compressed evenly. Do not overtighten the bolts.
Replace the pipe to flange gasket between the exhaust pipe and the exhaust manifold with a new part.
Reattach the exhuast pipe to the hangers.
Install the 3 bolts connecting the pipe flange to the exhaust manifold.
Fill the engine with oil.

Sep 15, 2009 | 2001 GMC Yukon

1 Answer

Replacing the water pump


2.4L Engine
  1. Disconnect the negative battery cable
  2. Detach the Oxygen (O2) sensor electrical connector.
  3. Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for a more complete coolant drain.
  4. Remove upper exhaust manifold heat shield.
  5. Remove the bolt that attaches the exhaust manifold brace to the manifold.
  6. Remove the lower exhaust manifold heat shield.
  7. Break the manifold-to-exhaust pipe spring loaded bolts loose using a 13mm box wrench.
  8. Raise and safely support the vehicle.

NOTE It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved, it will cause the exhaust pipe to twist and bind up the bolt as it is removed.
  1. Unfasten the two radiator outlet pipe-to-water pump cover bolts.
  2. Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
    1. Unscrew either bolt clockwise 4 turns.
    2. Remove the other bolt.
    3. Remove the first bolt.

NOTE DO NOT rotate the flex coupling more than 4° or damage may occur.
  1. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  2. Remove the radiator outlet pipe from the oil pan and transaxle. Leave the lower radiator hose attached and pull down on the outlet pipe to remove it from the water pump. Leave the radiator outlet pipe hang.
  3. Carefully lower the vehicle.
  4. Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.
  5. Remove the front timing chain cover and the chain tensioner. For details, please refer to the procedure located later in this section.
  6. Unfasten the water pump-to-cylinder block bolts. Remove the water pump-to-timing chain housing nuts. Remove the water pump and cover mounting bolts and nuts. Remove the water pump and cover as an assembly, then separate the two pieces.
87953070.gif Water pump and cover mounting—2.4L engine
Click to Enlarge
To install:
  1. Thoroughly clean and dry all mounting surfaces, bolts and bolt holes. Using a new gasket, install the water pump to the cover and tighten the bolts finger-tight.
  2. Lubricate the splines of the water pump with clean grease and install the assembly to the engine using new gaskets. Install the mounting bolts and nuts finger-tight.
  3. Lubricate the radiator outlet pipe O-ring with antifreeze and slide the pipe onto the water pump cover. Install the bolts finger-tight.
  4. With all gaps closed, tighten the bolts, in the following sequence, to the proper values:
    1. Pump assembly-to-chain housing nuts:19 ft. lbs. (26 Nm).
    2. Pump cover-to-pump assembly: 106 inch lbs. (12 Nm).
    3. Cover-to-block, bottom bolt first: 19 ft. lbs. (26 Nm).
    4. Radiator outlet pipe assembly-to-pump cover: 125 inch lbs. (14 Nm).
  5. Using new gaskets, install the exhaust manifold. Make sure to following the tightening sequence and torque specifications given in the exhaust manifold procedure located in this section.
  6. Raise and safely support the vehicle.
  7. Index the exhaust manifold bolts into the exhaust pipe flange.
  8. Connect the exhaust pipe to the manifold. Install the exhaust pipe flange bolts evenly and gradually to avoid binding. Turn the bolts in until fully seated.
  9. Connect the radiator outlet pipe to the transaxle and oil pan.
  10. Install the timing chain tensioner and front cover.
  11. Install the lower heat shield.
  12. Carefully lower the vehicle.
  13. Fasten the bolt that attaches the exhaust manifold brace to the manifold.
  14. Tighten the manifold-to-exhaust pipe nuts to specification.
  15. Install the upper heat shield.
  16. Attach the oxygen sensor connector.
  17. Fill the radiator with coolant until it comes out the heater hose outlet at the thermostat housing. Then connect the heater hose. Leave the radiator cap off.
  18. Connect the negative battery cable, then start the engine. Run the vehicle until the thermostat opens, fill the radiator and recovery tank to their proper levels, then turn the engine OFF.
  19. Once the vehicle has cooled, recheck the coolant level, then install the radiator cap.

3.1L Engine
  1. Disconnect the negative battery cable.
  2. Properly drain the cooling system into a suitable container.
  3. Loosen, but do not remove, the water pump pulley bolts.
  4. Remove the serpentine belt.
  5. Unfasten the water pump pulley bolts, then remove the pulley.
  6. Remove the five water pump mounting bolts, then remove the water pump.
To install:
86883115.gif View of the water pump mounting and bolt tightening specifications—3.1L engine shown
Click to Enlarge
  1. Clean all the gasket surfaces completely.
  2. Apply a thin bead of sealer around the outside edge of the water pump along the gasket sealing area, then install the gasket onto the water pump.
  3. Position the water pump on the engine, then tighten the water pump mounting bolts to 89 inch lbs. (10 Nm).
  4. Install the water pump pulley and finger-tighten the pulley bolts.
  5. Install the serpentine belt.
  6. Tighten the water pump pulley bolts to 18 ft. lbs. (25 Nm).
  7. Fill the cooling system.
  8. Connect the negative battery cable, then start the engine. Let the engine run until it reaches normal operating temperature, then check for leaks and coolant level. Add coolant, if necessary, then turn the engine OFF.

Aug 20, 2009 | 1997 Chevrolet Malibu

1 Answer

I'm trying to determine the (correct)


Check and review this info: ZJ-Secc-11-Exhaust-System-and-Intake-Manifold

In this pages find several graphics that can be help you.

Good luck!!!

Jul 11, 2009 | 1995 Jeep Grand Cherokee

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