EXHAUST MANIFOLD REMOVAL

PROCEDURE


  1. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

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  2. REMOVE ENGINE UNDER COVER RH

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  3. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

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  4. REMOVE ENGINE UNDER COVER LH

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  5. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    1. A01W5R1

      Disconnect the heated oxygen sensor connector.

    2. A01W08Y

      Remove the 2 bolts, 2 compression springs, 2 nuts and front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and center exhaust pipe assembly.

    3. Disconnect the front exhaust pipe assembly (TWC: Rear Catalyst) from the exhaust pipe support.

    4. Remove the 2 exhaust pipe gaskets from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst).

  6. REMOVE COOL AIR INTAKE DUCT SEAL

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  7. REMOVE INLET AIR CLEANER ASSEMBLY

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  8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01VZJ4

      Remove the 4 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  9. REMOVE AIR FUEL RATIO SENSOR

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  10. REMOVE EGR PIPE CONNECTOR


    1. A01W2BO

      Remove the 4 bolts, nut and EGR pipe connector from the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly.

      Text in Illustration
      B001O8N Bolt
      B001OAO Nut
    2. A01W3AF

      Remove the 2 EGR cooler gaskets from the EGR pipe connector.

  11. REMOVE MANIFOLD STAY


    1. A01W538

      Remove the bolt, nut and manifold stay from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly.

  12. REMOVE NO. 2 MANIFOLD STAY


    1. A01W3C8

      Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly.

  13. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. A01W1ZQ

      Remove the 5 nuts and exhaust manifold converter sub-assembly (TWC: Front Catalyst) from the cylinder head sub-assembly.

    2. A01W53I

      Remove the exhaust manifold gasket from the cylinder head sub-assembly.

  14. REMOVE NO. 1 MANIFOLD CONVERTER INSULATOR


    1. A01W5LI

      Remove the 3 bolts and No. 1 manifold converter insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  15. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01W0U3

      Remove the 2 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  16. REMOVE STUD BOLT

    Tech Tips

    If a stud bolt is deformed or the threads are damaged, replace it.


    1. A01W1QP

      Using an E8 "TORX" socket wrench, remove the stud bolt from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).