EXHAUST MANIFOLD REMOVAL


  1. REMOVE NO. 1 ENGINE UNDER COVER

  2. REMOVE NO. 2 ENGINE UNDER COVER

  3. REMOVE FRONT NO. 3 ENGINE UNDER COVER


    1. A01JASK

      Remove the 4 clips and front No. 3 engine under cover.

  4. REMOVE FRONT CENTER FLOOR BRACE


    1. A01JBGZ

      Remove the 4 bolts and front center floor brace.

  5. DRAIN COOLANT (for Engine with Exhaust Heat Recirculation System)

    Note

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


    1. Loosen the radiator drain cock plug and drain the coolant.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the local regulations.

    2. Loosen the cylinder block drain cock plug.

      Tech Tips

      The plug is on the back of the generator on the exhaust manifold side.

      A01JB2ZE01
      Text in Illustration
      *1 Reservoir Tank Cap *2 Cylinder Block Drain Cock Plug
      *3 Radiator Drain Cock Plug *4 Air Release Valve

  6. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)


    1. A01JA56

      Disconnect the 3 clamps and oxygen sensor connector.

    2. A01JC0H

      Disconnect the 2 heater water hoses.

    3. A01JC5E

      Remove the 4 bolts and 4 compression springs.

    4. Remove the front exhaust pipe assembly from the 3 exhaust pipe supports.

    5. Remove the 2 gaskets from the front exhaust pipe assembly and exhaust manifold.

  7. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)


    1. A01JC5E

      Remove the 4 bolts and 4 compression springs.

    2. Remove the front exhaust pipe assembly from the 3 exhaust pipe supports.

    3. Remove the 2 gaskets from the front exhaust pipe assembly and exhaust manifold.

  8. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR


    1. A01JB3F

      Remove the 3 nuts and No. 1 floor heat insulator.

  9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01J8R2

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  10. REMOVE AIR FUEL RATIO SENSOR NO.2


    1. A01JCNW

      Disconnect the air fuel ratio sensor connector and clamp.

    2. A01JBJ8E01

      Using SST, remove the air fuel ratio sensor.

      SST
      09224-00010

  11. REMOVE MANIFOLD STAY


    1. A01J9M6

      Remove the 3 bolts and manifold stay.

  12. REMOVE EXHAUST MANIFOLD


    1. A01J93S

      Remove the 7 nuts, exhaust manifold and 2 gaskets.

  13. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01J8M0

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