EXHAUST MANIFOLD REMOVAL


  1. REMOVE FRONT WHEEL RH

  2. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A017EFM

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 clips on the front of the V-bank cover sub-assembly. Continue rising the V-bank cover sub-assembly to disengage the clip on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

  3. REMOVE ENGINE UNDER COVER ASSEMBLY


    1. A017FPR

      Remove the 2 bolts and engine under cover assembly RR.

    2. A017FXN

      Remove the 2 bolts, 2 screws, 5 clips and engine under cover assembly.

  4. REMOVE NO. 1 ENGINE UNDER COVER


    1. A017D1W

      Remove the 6 bolts, 2 clips and No. 1 engine under cover.

  5. REMOVE NO. 2 ENGINE UNDER COVER


    1. A017CNJ

      Remove the 2 bolts and No. 2 engine under cover.

  6. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator cap sub-assembly, cylinder block drain cock plugs or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

    2. Loosen the cylinder block drain cock plug. (for Bank 1)

    3. Loosen the cylinder block drain cock plug. (for Bank 2, w/ Cylinder Block Drain Cock Plug)

    4. Remove the radiator cap sub-assembly.

      A017CW8E03
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Cylinder Block Drain Cock Plug (for Bank 1)
      *3 Cylinder Block Drain Cock Plug (for Bank 2, w/ Cylinder Block Drain Cock Plug) *4 Radiator Drain Cock Plug
      *5 Air Drain Cock Plug *6 Air Drain Plug

      Tech Tips

      Collect the engine coolant in a container and dispose of it according to the regulations in your area.

  7. DISCONNECT NO. 1 RADIATOR HOSE


    1. A017EYO

      Disconnect the No. 1 radiator hose from the radiator.

  8. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. A017F8BE01

      Disconnect the hose [A].

    2. Remove the 2 bolts [B] and radiator reserve tank assembly.

  9. REMOVE NO. 2 OIL LEVEL DIPSTICK GUIDE


    1. A017BP5

      Remove the bolt and the No. 2 oil level dipstick guide.

  10. REMOVE AIR FUEL RATIO SENSOR NO.2 (for Bank 2 Sensor 1)


    1. A017BMP

      Disconnect the air fuel ratio sensor connector and remove the clamp.

    2. A017CEN

      Using SST, remove the sensor from the exhaust manifold sub-assembly LH.

      SST
      09224-00010

  11. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A017G2I

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

  12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)


    1. A017FGM

      Depress the brake pedal and hold it.

    2. Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.

      Tech Tips

      Put a piece of cloth or equivalent into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover.

    3. A017FC7E01

      Place matchmarks on the rear propeller shaft and rear drive pinion flange sub-assembly.

    4. Remove the 4 nuts, 4 bolts and 4 washers.

    5. A017G71

      Remove the 4 bolts and 4 adjusting shims.

    6. A017DKO

      Using a brass bar and a hammer, remove the propeller shaft with center bearing shaft assembly.

    7. A017G8QE01

      Insert SST into the transfer to prevent oil leakage.

      SST
      09325-20010

  13. REMOVE TAIL EXHAUST PIPE ASSEMBLY


    1. A017DZ8

      Remove the 2 bolts and 2 compression springs.

    2. Disconnect the exhaust pipe support and remove the tail exhaust pipe assembly.

    3. Remove the gasket from the center exhaust pipe assembly.

  14. REMOVE CENTER EXHAUST PIPE ASSEMBLY


    1. A017EM8

      Remove the 2 bolts and 2 compression springs.

    2. Disconnect the 3 exhaust pipe supports and remove the center exhaust pipe assembly.

    3. Remove the gasket from the No. 3 exhaust pipe sub-assembly.

  15. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY


    1. A017C8S

      Remove the 3 clamps and disconnect the heated oxygen sensor (for bank 1 sensor 2) connector.

    2. A017F2Y

      Remove the 2 bolts, 2 nuts and front No. 3 exhaust pipe sub-assembly.

    3. Remove the 2 gaskets from the front No. 3 exhaust pipe sub-assembly.

  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A017CJP

      Disconnect the heated oxygen sensor (for bank 2 sensor 2) connector.

    2. A017EQE

      Loosen the bolt.

    3. Remove the 2 nuts and front exhaust pipe assembly.

    4. Remove the gasket from the front exhaust pipe assembly.

  17. REMOVE NO. 2 MANIFOLD STAY


    1. A017BAW

      Remove the bolt, nut and No. 2 manifold stay.

  18. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A017FR6

      Remove the 6 nuts and exhaust manifold sub-assembly LH.

    2. Remove the gasket.

  19. REMOVE MANIFOLD STAY


    1. A017DFR

      Remove the bolt, nut and manifold stay.

  20. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A017FX3

      Disconnect the air fuel ratio sensor (for bank 1 sensor 1) connector and remove the clamp.

    2. A017D7L

      Remove the 6 nuts and exhaust manifold sub-assembly RH.

    3. Remove the gasket.

  21. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)


    1. A017CYHE01

      Using SST, remove the air fuel ratio sensor from the exhaust manifold sub-assembly RH.

      SST
      09224-00010