Vehicles With Manual Transmission

Right Front Exhaust Pipe With Catalytic Converter, Removing And Installing (Vehicles With Manual Transmission)

Removing







- Remove rear engine cover (arrows).







- Remove cover -1- in engine compartment (right side).







- Remove bolts (arrows).
- Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air guide.
- Remove air guide -2-.







- Remove air filter housing (arrows).







- Remove bolts for holding plate -3- for solenoid valves (arrows).
- Disconnect electrical harness connector at Mass Air Flow (MAF) sensor.
- Remove hose -4- from air duct -2-.







- Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
- Disconnect hose -1- from air duct.

NOTE: Illustration depicts air guide from rear with the engine removed.







- Remove harness connectors -1- to -4- from bracket at right of bulkhead.
- Disconnect electrical harness connectors -1- and -4-.
- Guide wires to the oxygen sensors downward.







- Remove nut -2- which is accessible from top for exhaust pipe/exhaust manifold.

NOTE: Illustration is shown with engine removed.

- Remove right front wheel







- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.







- Remove bolts or quick-release screws -1- and -2- and remove front noise insulation.
- Remove quick-release screws -3- and remove rear noise insulation, if installed.







- Remove front vehicle floor crossmember -1- to 4-.

NOTE: Flex joint in front exhaust pipe must not be bent more than 10 degree, otherwise it may be damaged.







- Disconnect exhaust system at right double clamp (right arrow).







- Remove heat shield -1- for right drive axle.







- Remove bracket for front exhaust pipe (arrow).
- Expose oxygen sensor wires.







- Remove nuts -1- and -3- which are accessible from bottom for front exhaust pipe/exhaust manifold.

NOTE: Illustration is shown with engine removed.

- Remove front exhaust pipe with catalytic converter.

Installing
Installation is the reverse of removal, noting the following:

NOTE:
- All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Replace gaskets and self-locking nuts.
- Wires of oxygen sensors must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.

- Install exhaust system free of stress.

NOTE: Individual mounting components for exhaust system to transmission on vehicles with manual transmission, See Fig. 4.

Fig. 4 Individual right mounting components for vehicles with manual transmission







1 - Spacer sleeve
2 - Strap
3 - Compression spring
4 - Washer
5 - Bolt (25 Nm)
6 - Spacer sleeve
7 - Buffer
8 - Spacer sleeve
9 - Self-locking nut (25 Nm)

Tightening torques

Component Nm
Front exhaust pipe with catalytic converter to exhaust manifold 27
Front exhaust pipe with catalytic converter to hanging strap 25
Drive axle protection to transmission 23.