EXHAUST MANIFOLD REMOVAL

PROCEDURE

1. REMOVE NO. 1 ENGINE COVER

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2. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY

   
   

   1. 

      Remove the oil level dipstick sub-assembly from the oil level dipstick guide.

3. REMOVE OIL LEVEL DIPSTICK GUIDE

   
   

   1. 

      Remove the bolt and oil level dipstick guide from the cylinder head cover sub-assembly and oil pan sub-assembly.

4. REMOVE OIL LEVEL DIPSTICK GUIDE O-RING

   
   

   1. 

      Remove the oil level dipstick guide O-ring from the oil level dipstick guide.

5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

   
   

   1. 

      Remove the 2 bolts, 2 nuts and No. 1 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly.

6. DISCONNECT FRONT EXHAUST PIPE ASSEMBLY

   
   

   1. 

      Disconnect the heated oxygen sensor connector.

   2. Disengage the clamp to separate the heated oxygen sensor wire from the wire harness clamp bracket.

   3. 

      Remove the 2 bolts and 2 compression springs to disconnect the front exhaust pipe assembly from the exhaust manifold converter sub-assembly.

   4. Remove the exhaust pipe gasket from the exhaust manifold converter sub-assembly.

7. REMOVE AIR FUEL RATIO SENSOR

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8. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

   
   

   1. 

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly.

9. REMOVE MANIFOLD STAY

   
   

   1. 

      Remove the bolt, nut and manifold stay from the exhaust manifold converter sub-assembly and cylinder block sub-assembly.

10. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    
    

    1. 

       Remove the 9 nuts and exhaust manifold converter sub-assembly from the exhaust cooler assembly and EGR pipe assembly.

11. REMOVE EXHAUST MANIFOLD GASKET

    
    

    1. 

       Remove the exhaust manifold gasket from the exhaust cooler assembly.

12. REMOVE EGR PIPE GASKET

    
    

    1. 

       Remove the EGR pipe gasket from the EGR pipe assembly.