EXHAUST MANIFOLD REMOVAL


  1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  2. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. A003VJD

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003Z14

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  4. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. A003Y4M

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003WN3

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

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


    1. A003WMR

      Remove the 2 bolts and cowl body mounting reinforcement LH.

  7. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. A003YWK

      Remove the 2 bolts and cowl body mounting reinforcement RH.

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


    1. A003W0I

      Disengage the clamp and separate the wire harness.

    2. A003WSZ

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003YRF

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

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


    1. A003X05

      Disengage the clamp and separate the wire harness.

    2. A003X62

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003ZGV

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

  10. REMOVE NO. 2 CYLINDER HEAD COVER


    1. A003WMME01

      Remove the 3 clips and No. 2 cylinder head cover.

      Note


      • Disengage the clips in the order shown in the illustration.

      • When disengaging clip 3, hold the end of the cover behind clip 3 and lift the cover straight up.

      • Attempting to disengage both front and rear clips at the same time may cause the cover to break.

      • Pull the cover straight up to remove. Attempting to pull the cover forward or pull it up by holding the left and right ends may cause the cover to break.

  11. REMOVE NO. 1 ENGINE UNDER COVER

  12. REMOVE FRONT NO. 3 ENGINE UNDER COVER


    1. A003X24

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

  13. REMOVE FRONT CENTER FLOOR BRACE


    1. A003XBU

      Remove the 4 bolts and front center floor brace.

  14. DRAIN COOLANT (w/ Exhaust Heat Recirculation System)

    Note

    Do not remove the reserve tank cap 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. A003Z8O

      Loosen the radiator drain cock plug.

      Tech Tips

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

    2. Remove the reserve tank cap and drain the coolant.

      A003ZHYE01
      Text in Illustration
      *1 Reserve Tank Cap *2 Radiator Drain Cock Plug

  15. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst (w/ Exhaust Heat Recirculation System))

    CAUTION:

    Perform this procedure when the coolant is not hot.


    1. A003YYM

      Disconnect the 3 clamps and oxygen sensor connector.

    2. A003WKV

      Disconnect the 2 heater water hoses.

    3. A003VR3

      Remove the 4 bolts and 4 compression springs.

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

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

  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst (w/o Exhaust Heat Recirculation System))


    1. A003WND

      Disconnect the 3 clamps and oxygen sensor connector.

    2. A003WCG

      Remove the 4 bolts and 4 compression springs.

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

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

  17. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR


    1. A003WGL

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

  18. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A003YPLE01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

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

  19. REMOVE AIR FUEL RATIO SENSOR NO.2


    1. A003ZOQ

      Disconnect the air fuel ratio sensor connector and clamp.

    2. A003VHUE03

      Using SST, remove the air fuel ratio sensor.

      SST
      09224-00010

  20. REMOVE MANIFOLD STAY


    1. A003ZQD

      Remove the 3 bolts and manifold stay.

  21. REMOVE EXHAUST MANIFOLD


    1. w/ EGR System:


      1. A003WMG

        Remove the 7 nuts, exhaust manifold and 2 gaskets.

    2. w/o EGR System:


      1. A003YA8

        Remove the 5 nuts, exhaust manifold and gasket.

  22. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A003YOGE02
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

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