Right Front Exhaust Pipe With Catalytic Converter, Removing and Installing (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 shows the 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 oxygen sensors downward.







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

NOTE: Illustration is shown with engine removed.

- Remove right front wheel







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







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







- Remove bolts -1- through -4- and remove crossmember.

NOTE: Flex joint in front exhaust pipe must not be bent more than 10 degrees, 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- for front exhaust pipe/exhaust manifold which are accessible from bottom.

NOTE: Illustration is shown with engine removed.

- Remove front exhaust pipe with catalytic converter.

Installing
Installation is 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.

- Oxygen sensor wiring must always be secured in the same position when installing so that contact with the exhaust pipe is avoided.
- Replace gaskets and self-locking nuts.
- Install exhaust system free of stress.

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

Tightening torques

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