EXHAUST MANIFOLD REMOVAL


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  2. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. A01JAL3

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  3. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for RHD)


    1. A01JDA9

      Remove the 3 bolts and cowl body mounting reinforcement LH.

  4. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A01JCF9

      Disengage the clamp and separate the wire harness.

    2. A01J9NS

      Disengage the claw and bend the No. 1 heater air duct splash shield seal.

    3. A01JC64

      Disengage the claw and bend the water guard plate RH.

    4. A01J9P5

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  5. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A01JAH2

      Disengage the clamp and separate the wire harness from the outer cowl top panel sub-assembly.

    2. A01JB4QE01

      Disengage the clamp*1 and disconnect the connector (w/ Windshield Deicer).

    3. Disengage the clamp*2 and separate the wire harness from the outer cowl top panel sub-assembly.

    4. A01J9F7

      Disengage the claw and bend the No. 1 heater air duct splash shield seal.

    5. A01JBZC

      Disengage the claw and bend the water guard plate RH.

    6. A01J9HT

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  6. REMOVE NO. 1 ENGINE UNDER COVER

  7. REMOVE NO. 2 ENGINE UNDER COVER

  8. REMOVE FRONT NO. 3 ENGINE UNDER COVER


    1. A01JASK

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

  9. REMOVE FRONT CENTER FLOOR BRACE


    1. A01JC0B

      Remove the 4 bolts and front center floor brace.

  10. 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.

      A01J9RAE01
      Text in Illustration
      *1 Reservoir Tank Cap *2 Radiator Drain Cock Plug

      Tech Tips

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

  11. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst (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 (TWC: Front and Rear Catalyst) and exhaust manifold.

  12. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst (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 (TWC: Front and Rear Catalyst) and exhaust manifold.

  13. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR


    1. A01JB3F

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

  14. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01JCM4E01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

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

  15. REMOVE AIR FUEL RATIO SENSOR


    1. A01JCNW

      Disconnect the air fuel ratio sensor connector and clamp.

    2. A01JBJ8E01

      Using SST, remove the air fuel ratio sensor.

      SST
      09224-00010

  16. REMOVE MANIFOLD STAY


    1. A01J9M6

      Remove the 3 bolts and manifold stay.

  17. REMOVE EXHAUST MANIFOLD


    1. w/ EGR System:


      1. A01J93S

        Remove the 7 nuts, exhaust manifold and 2 gaskets.

    2. w/o EGR System:


      1. A01JAHW

        Remove the 5 nuts, exhaust manifold and gasket.

  18. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01J8WPE02
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

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