Exhaust Manifold and Exhaust Pipe with Catalytic Converter

Exhaust Manifold and Exhaust Pipe with Catalytic Converter

• After exhaust system installation work, ensure system is spaced far enough away from body. If necessary, loosen the flange on the catalytic converter and realign mufflers and exhaust pipes. Refer to --> [ Aligning Exhaust System ] Aligning Exhaust System.

Special tools, testers and auxiliary items required

• Ring spanner 7 piece set for oxygen sensor (3337)

Removing

- Disconnect batteries..

With One Piece Intake Manifold

- Remove vacuum hoses - 1 through 4 - from intake manifold.





- Remove air filter housing with air inlet hose to throttle valve control module (J338).

- Remove throttle valve control module (J338) from intake manifold.

With Two Piece Intake Manifold

- Remove upper intake manifold. Refer to --> [ Upper Intake Manifold ] Upper Intake Manifold.

Continuation for All

- Disconnect oxygen sensor connectors - 1 through 4 -.





- Using ring spanner set (3337), remove Heated Oxygen Sensor (HO2S) (G39) and HO2S 2 (G108) in front of catalytic converters.

- Next, remove heat shield with intake manifold support.

- Now remove Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) (G130) and O2S 2 behind TWC (G131) behind catalytic converters.

- Raise the vehicle.

- Identify both exhaust pipe flanges, this makes assembly later easier.

- Remove nuts on flanges.

- Remove bracket to transmission --> [ (Item 13) Bolt, 25 Nm ] Exhaust Manifold, Catalytic Converter and Components Assembly Overview.

- Unbolt flange to exhaust manifold.

To loosen or tighten nuts more easily, shorten a commercially available 16 mm open end wrench to approximately 11 cm handle length.

- First remove exhaust pipe with catalytic converter from cylinders 4 to 6, then from cylinders 1 to 3.

- Remove exhaust manifold.

Installing

• When installing exhaust pipes, ensure that the flange connection after the catalytic converter seals tightly. Leaks in this area produce pulsations in the exhaust. This allows ambient air to reach the lambda probe after catalytic converter and the lambda regulation will be disturbed.

• Adjust the exhaust system so that there is sufficient clearance to the transmission and subframe.

The rest of the assembly is basically a reverse of the disassembling sequence.