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.