Installing exhaust manifold

DeVille, Eldorado, Seville 1999-2005

• REMOVAL & INSTALLATION

Cylinder Head

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Removal & Installation

Left Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Properly relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   Negative battery cable Exhaust manifold Alternator Water crossover Intake manifold Valve cover Timing cover Secondary camshaft drive chain Power steering return hose retaining bolt from the cylinder head 3 M6 external drive bolts from the front portion of the cylinder head 10 M11 internal drive cylinder head bolts Cylinder head and gasket.
   
5. Clean the head mating surfaces.

To install:

Fig. Left cylinder head bolt torque sequence-4.6L engine

1. Install the cylinder head with a new gasket. Lubricate the bolts with engine oil prior to installation.
2. Torque the M11 bolts in sequence as follows:
   1. Step 1: 30 ft. lbs. (40 Nm), plus an additional 70 degrees
   2. Step 2: Turn an additional 60 degrees
   3. Step 3: Turn an additional 60 degrees (total 190 degrees)
   
   
3. Torque the M6 bolts to 106 inch lbs. (12 Nm)
4. Install or connect the following:
   
   Power steering return hose retaining bolt to the cylinder head and tighten to 37 ft. lbs. (50 Nm) Secondary camshaft drive chain Timing cover Valve cover Intake manifold Water crossover Exhaust manifold Negative battery cable
   
5. Change the oil and filter.
6. Fill the cooling system.

Right Side

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Properly relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   Negative battery cable Exhaust manifold Water crossover Intake manifold Valve cover Timing cover Secondary camshaft drive chain Electrical connector from the Engine Coolant Temperature (ECT) sensor Nut attaching the coil cassette ground wire to the cylinder head Bolt attaching the exhaust crossover pipe to the cylinder head Bolt attaching the right transaxle mount bracket to the cylinder head Bolt attaching the rear transaxle brace to the transaxle Nuts attaching the rear transaxle brace to the cylinder head Rear transaxle brace 3 M6 external drive bolts from the front portion of the cylinder head 10 M11 internal drive cylinder head bolts Cylinder head and gasket
   
5. Clean the head mating surfaces.

To install:

Fig. Right cylinder head bolt torque sequence- 4.6L engine

1. Install the cylinder head with a new gasket. Lubricate the bolts with engine oil prior to installation.
2. Torque the M11 bolts in sequence as follows:
   1. Step 1: 30 ft. lbs. (40 Nm), plus an additional 70 degrees.
   2. Step 2: Turn an additional 60 degrees.
   3. Step 3: Turn an additional 60 degrees (total 190 degrees).
   
   
3. Torque the M6 bolts to 106 inch lbs. (12 Nm).
4. Install or connect the following:
   
   Rear transaxle brace over the studs located at the rear of the right cylinder head Nuts attaching the rear transaxle brace to the cylinder head, loosely Bolts attaching the rear transaxle braces to the transaxle and tighten to 37 ft. lbs. (50 Nm) Nuts attaching the rear transaxle brace to the cylinder head and tighten 37 ft. lbs. (50 Nm) Electrical connector to the ECT sensor Bolt attaching the exhaust crossover pipe to the cylinder head and tighten to 18 ft. lbs. (25 Nm) Nut attaching the coil cassette ground wire to the cylinder head and tighten to 13 ft. lbs. (17 Nm) Secondary camshaft drive chain Timing cover Valve cover Intake manifold Water crossover Exhaust manifold Negative battery cable
   
5. Change the oil and filter.
6. Fill the cooling system.

let me see if i can get some info 4 you.

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REMOVAL

1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose (between the air cleaner and the head cover).
3. Remove the air-intake hose.
4. Remove the vacuum hose, fuel hose and coolant hose.
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the power steering oil pump and bracket.
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold assembly.
10. Remove the coolant pump pulley and the crankshaft pulley.
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the head cover.


15. Remove the cylinder head assembly. The cylinder head bolts should be removed by using Special Tool, Cylinder Head Bolt Wrench (09221-32001) or equivalent, in the sequence as shown in the illustration in two or three steps.
16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: Make sure that the gasket pieces do not fall in the engine.

INSTALLATION

1. Clean all gasket surfaces of the cylinder block and the cylinder head.
2. Install a new cylinder head gasket onto the cylinder head assembly. Apply sealant to the gasket and do not reuse the old cylinder head gasket.


3. Install the cylinder head bolts. Starting at top center, tighten all cylinder head bolts in sequence as shown in illustration, using the Cylinder Head Bolt Wrench (09221 - 32001) or equivalent. Repeat the procedure, re-tightening all cylinder head bolt to the specified torque. (torque spec is Cold Engine 105-115 Nm (76-83 ft lb) )
4. Install the timing belt tensioner pulley.
5. Install the timing belt on the camshaft sprocket, making sure that the tension side is tightened by turning the camshaft sprocket in reverse, all timing marks are in alignment.
6. Adjust the timing according to "Timing Belt"
7. Install the rocker cover and tighten the bolts to the specified torque. Tightening torque: Rocker cover belt:

2.5-3.5 Nm (25-35 kg.cm, 2-3 ft. lbs.)

8. Install the timing belt cover.
9. Install the new intake manifold gasket and the intake manifold. Tighten the nuts and bolts to the specified torque.
10. Install the new exhaust manifold gasket and the exhaust manifold. Tighten the exhaust manifold attaching nuts to the specified torque.
11. Install the surge tank and tighten the nuts bolts to the specified torque.
12. Install the power steering oil pump and bracket.
13. Install the ignition coil.
14. Install the air intake hose.
15. Connect the vacuum hose, fuel hose and water hose.
16. Install breather hose.

The bolts should have thread lock on them when installing, and the torque is done in 2 steps. 33 ft lbs. and then 90 deg. after that on the second pass. 3.1L Engine CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. LEFT SIDE (FRONT)

1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Drain the cooling system into a suitable container.
4. Disconnect the top half of the air cleaner assembly, then remove the throttle body air inlet duct.
5. Remove the exhaust crossover pipe heat shield and crossover pipe.
6. Disconnect the spark plug wires from spark plugs and looms then route the wires out of the way.
7. Remove the rocker arm (valve) covers.
8. Remove upper intake plenum and lower intake manifold.
9. Remove the left side exhaust manifold.
10. Remove oil level indicator tube. NOTE: When removing the valve train components they must be kept in order for installation in the same locations they were removed from.
    
11. Remove rocker arms nut, rocker arms, balls and pushrods.
12. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket. To install:
    
13. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
14. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP are showing.
15. Coat the bolt threads lightly with sealer, then install finger-tight.
16. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
17. Install the pushrods, rocker arms, balls and rocker arm nuts in their proper locations. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
18. Install the lower intake manifold and upper intake plenum.
19. Install the rocker arm (valve) covers.
20. Install the oil level indicator tube. Insert the dipstick.
21. Connect the spark plug wires to spark plugs and looms.
22. Install the left side exhaust manifold.
23. Install the exhaust crossover pipe and heat shield.
24. Refill the cooling system.
25. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
26. Connect negative battery cable.
27. Start vehicle and verify that there are no leaks. Fig. 20: Cylinder head mounting and bolt tightening sequence - 3.1L engine
    

RIGHT CYLINDER HEAD (REAR) CAUTION
Fuel Injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Relieve the fuel system pressure.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove the top half of the air cleaner assembly and remove the throttle body air inlet duct.
5. Remove the exhaust crossover pipe heat shield and crossover pipe.
6. Raise and safely support the vehicle.
7. Detach the Oxygen (O2) sensor connector.
8. Disconnect the exhaust pipe from the exhaust manifold.
9. Remove the right side exhaust manifold.
10. Carefully lower the vehicle.
11. Disconnect the spark plug wires from spark plugs and wire looms and route the wires out of the way.
12. Remove the rocker arm (valve) covers.
13. Remove upper intake plenum and lower intake manifold. NOTE: When removing the valve train components they must be kept in order for installation in the same locations they were removed from.
    
14. Remove rocker arms nut, rocker arms, balls and pushrods.
15. Unfasten the cylinder head bolts evenly, then remove the cylinder head from the engine compartment. Remove and discard the gasket. To Install:
    
16. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
17. Place the cylinder head gasket in position over the dowel pins on the cylinder block so the words THIS SIDE UP showing.
18. Coat the bolt threads lightly with sealer, then install finger-tight.
19. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
20. Install the pushrods loosely retained with the rocker arm assemblies. Make sure all pushrods are in the correct locations. Coat the ends of the pushrods with prelube. The intake rods are marked yellow and are 5 3?4 inch long. The exhaust pushrods are marked green and 6 inches long. balls and rocker arm nuts. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
21. Install the lower intake manifold and upper intake plenum.
22. Install the rocker arm (valve) covers.
23. Connect the spark plug wires to spark plugs and wire looms.
24. Raise and safely support the vehicle.
25. Install the exhaust manifold.
26. Connect the exhaust pipe to the exhaust manifold.
27. Carefully lower the vehicle.
28. Connect the Oxygen (O2) sensor wiring.
29. Install the exhaust crossover pipe and heat shield.
30. Refill the cooling system.
31. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
32. Connect negative battery cable.
33. Start vehicle and verify that there are no leaks.

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

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.

3.4L Engine To Remove:

1. Remove the lower intake manifold.
2. Remove the exhaust crossover pipe.
3. If removing the right cylinder head, remove the catalytic converter from exhaust manifold.
4. If removing the left cylinder head, remove the engine oil dipstick and tube.
5. Remove the rocker arms and pushrods.
6. Remove and discard the cylinder head bolts.
7. Remove the cylinder head.
8. Clean the mating surfaces on the following items:
   • Cylinder head
   • Cylinder block
   • Intake manifold
9. Clean the cylinder block bolt threads.

NOTE: During disassembly, keep the valve train components together for proper location during assembly.
To Install:
NOTE: Coat the cylinder head bolt threads using thread sealer.

1. If removed, install the following components:
   • Exhaust manifold
   • Accessory studs
   • Spark plugs
2. Place the cylinder head gasket in position over the dowel pins. Ensure that the THIS SIDE UP note is showing.
3. Install the cylinder head. Cylinder head torque sequence ’99-‘00
   
   Cylinder head torque sequence ’01-05
   
   
4. Install the new cylinder head bolts.
   • Tighten the cylinder head bolts a first pass to 44 ft lb (60 Nm).
5. Tighten the cylinder head bolts in sequence an additional 95 degrees.
6. Install the intake gasket.
7. Install the pushrods and rocker arms.
8. Raise and support the vehicle.
9. Install the catalytic converter and dipstick tube and indicator if removed.
10. Lower the vehicle.
11. Install the exhaust crossover pipe.
12. Install the intake manifolds.
13. Connect negative battery cable.
14. Fill the cooling system.