REMOVAL & INSTALLATION
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. Obtain radio code card from customer. Note stored stations and restore them after connecting battery. Stored settings of on-board computer and clock will also be lost. All available cental keys must be recoded for cars with first generation infrared transmitter locking systems. |
- Remove center pipe to manifold flange bolts (1). (Scheme 1)
- Disconnect both oxygen sensor connectors. (Scheme 2)
- Remove retaining screws (1) for heat shield. (Scheme 3)
- Remove retaining screws (1) for heat shield. (Scheme 4) Remove heat shield (2). Note routing of wiring harness.
- Remove 8 retaining screws (1) at exhaust manifold. (Scheme 5) Remove exhaust manifold.
- To install, reverse removal procedure. Make sure that mating surfaces of cylinder head and manifold are clean. Fit new gaskets. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165772-S42107832882004090300000). Coat threads of center pipe to manifold flange bolts with copper paste.
Scheme 1
Scheme 2
Scheme 3
Scheme 4
Scheme 5
- Turn off ignition. Remove starter. See «STARTER»(ref-165772-S42290771202004090300000).
- Remove nut (1). (Scheme 6) Remove cable lug (2).
- Remove screws (1). (Scheme 7)
- Remove solenoid switch (1) and spring (2). (Scheme 8) Unhook pin (3).
- To install, reverse removal procedure. Check pin (3) for wear and apply grease. Tighten nut for cable lug to specification. See «TORQUE SPECIFICATIONS»(ref-165772-S42107832882004090300000). Do NOT turn cable lug while tightening down.
Scheme 6
Scheme 7
Scheme 8
Note. Numbers in text apply to numbers in figures. For clarity, some figures are shown on a removed engine.
- Switch off ignition. Disconnect battery.
- Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-165772-S29806097002004090300000).
- Remove bolt (1). (Scheme 9) Release retaining clip (2). Remove heat shield.
- Disconnect battery positive lead (1). (Scheme 10) Remove nut (2). Remove starter motor.
- To install, reverse removal procedure. Be careful of cable routing. Do NOT lay cable over solenoid switch. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165772-S42107832882004090300000).
