Right Exhaust Manifold With Catalytic Converter

Right Exhaust Manifold with Catalytic Converter

Special tools, testers and auxiliary items required

• Engine Support Bridge (10 - 222 A)

• Adapter (10 - 222 A /21)

• Drip Tray for Workshop Crane (VAS 6208)

• Engine Support Supplement Set (T40093)

Removing

• During installation, all cable ties must be re-installed at the same location.

CAUTION!
Risk of destroying electrical components when battery is disconnected.

• Observe measures when disconnecting battery.

- With ignition switched off, disconnect Battery Ground (GND) cable.

- Remove rear engine cover - arrows -.





- Drain coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Remove right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe.

- Remove ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt

- Remove generator.

- Remove right front muffler. Refer to => [ Right Front Muffler ] Right Front Muffler.

- Remove electrical harness connectors from bracket and disconnect it:





1. For Heated Oxygen Sensor (HO) (G39)

2. For Oxygen Sensor (O) Behind Three Way Catalytic Converter (TWO) (G130)

- Free up electrical wires to oxygen sensors.

• Ignore items - 3 and 4 -.

- Remove bolt - arrow - at torque support mount.





- Remove bolts - arrows -.





- Remove rubber seal - 1 - and remove plenum chamber covers - 2 and 3 -.





- Remove tower brace rear bolts - 3 -.





- Secure Engine Support Bridge (10 - 222 A /21) with Adapter (10 - 222 A /4) at suspension strut towers.

• Support for left and right side of vehicle is marked.

• The middle contact point - 2 - of the support is placed on the tower brace front bolts.

• The Adapters (10 - 222 A /21) are secured with the tower brace rear bolts - 3 -.

• The knurled thumb screw - 1 - must be turned downward far enough so that the contact plate rests on the strut tower.

- Install Adapter (10 - 222 A /4) with Adapters (T40093/6) on Adapters (10 - 222 A /21).





- Secure Spindles (10 - 222 A /11) at engine lifting eyes.

- Lightly tension engine with engine support bridge spindles.

- Remove left and right stabilizer bar mount bolts - 1 and 2 -.





- Remove bolts - 3 and 4 -.





• Ignore items - 1 and 2 -.

- Remove engine bracket bolts at left and right - arrows -.





- Remove engine carrier.

- Disconnect left and right electrical connector - 2 - on Level Control System Sensor.





• Ignore - 1 -.

- Lower engine/transmission assembly by dimension - a - by rotating Spindles (10 - 222 A /11).





• Dimension - a - = 30 mm maximum.

- Remove torque support bracket.





- Remove bolts - 2 to 5 -.

- Remove torque support.

• Ignore - 1 -.

- Disconnect right engine mount electrical connector - 2 -.





- Remove electrical wiring bracket from right engine support - 1 -.

- Remove bolts - arrows - and remove engine support with engine mount.

- Place Drip Tray for Workshop Crane (VAS 6208) under engine.





- Disconnect right coolant hose - arrow - and drain coolant.

- Remove nuts - 6 to 1 -.





• Lower securing strips remain installed.

- Remove bolt - 2 - and remove right exhaust manifold from below with catalytic converter toward front.





• Ignore - 1 -.

Installing

• Tightening specifications. Refer to => [ Exhaust Manifold Assembly Overview ] Exhaust Manifold Assembly Overview, => [ Left exhaust manifold tightening sequence ] Exhaust Manifold Assembly Overview, => [ Individual components of suspension, right
side ] Exhaust Manifold Assembly Overview.

Installation is in reverse order of removal, note the following:

• Replace gasket and self-locking nuts.

- Place new gasket onto stud bolts.

- Insert exhaust manifold in securing strips and tighten => [ Left exhaust manifold tightening sequence ] Exhaust Manifold Assembly Overview.





- Install torque support and torque support bracket. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.

- Install right front muffler. Refer to => [ Right Front Muffler ] Right Front Muffler.

- Install engine support with engine mount. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.

- Install generator.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Install subframe and engine carrier.

- Install stabilizer bar.

- Install right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe.

- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Removal and Replacement.

- Observe safety precautions after connecting battery.

- Fill with coolant => [ Filling ] Procedures.