I hate you guys for making me think this was a 2 banana job....




What a nightmare. I started yesterday and got as far as removing the mid pipe. I loosened the lower bolt on the starter but could not budge the upper. I didn't have a 6 point offset wrench and was starting to round the bolt so I stopped to reassess.
Then I made the mistake of looking at the gasket and counting 14 bolt holes. After looking at the manifold over and over and over I am like I can't see 14 nuts. No way am I trying this. So I put it all back together and decided to take it somewhere to have it done.
Today I re-read the instructions and realized there are only 10 of the 14 holes used. Since I had left the outer Great Value heat shield and the 2 flaps off, I took another look. I could see 9 of the 10 nuts and knew where the 10th was. So tore it all back apart and tried to get the midpipe all of the way out. Wasn't happening. So shoved it back as far as possible and started on the manifold. Got a nice snap as 2 nuts broke free and no noise at all from the rest. The 2 on the front came off way too easily but who's complaining. (there was oil seepage around that part of the gasket so....) After a 15 min battle I was able to get the manifold twisted past the midpipe and out of the way. Removed the inner Great Value heat shield, popped the lower bolt loose and then nothing. That top bolt wasn't budging. I didn't have any 6 point wrenches so had to resort to a ratchet and socket. But even with the coolant hoses loose I could only get a short 1/4" ratchet in there. Still couldn't budge it. So took a 13mm deep socket and a 3" extension, slid it over the handle and that gave me just enough leverage to pop it.
Got the starter out, new one in and realized that the locking tab on the single wire hookup had broken off somewhere. So double zipped tied that connector cause I don't ever want to go back in there and continued on. Spent way too long trying to get the manifold back up and into place. Getting the nuts off of the manifold was pretty easy. Getting them back on is like solving a Rubik's cube blindfolded. What a pain. Finally got those torqued up. Put the dipstick tube in then tried to put the outer heat shield in place. DON'T Do That. You can't get the front bolt into place because it is behind the dipstick. Loosened it back up got the heat shield bolted up and tightened the dipstick back up.
Everything else went pretty smoothly except the front O2 sensor connector has slipped off the metal bracket and I couldn't for the life of me get it back on. Hopefully that won't cause any issues later.
Engine fired right up. Lots of smoke from the penetrating oil. Smells terrible. Took her around the block, put the skids back in place (I had done an oil change yesterday while the front end was up).
I would rank this job as annoying as the Valley Plate fix. I bow to you guys that could do this in a few hours. I have about 12 hours in over 2 days and 2 attempts. And this was preventative maintenance. 2009 with 165K on the clock. Have had the started for 4 years. Figured it was time.