Exhaust Manifold and Primary Catalytic Converters

Exhaust Manifold and Primary Catalytic Converters

Special tools, testers and auxiliary items required

• Ring Spanner 7-piece Set (3337)

Removing

- Disconnect the battery.

With a One Piece Intake Manifold

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





- Remove the air filter housing with the intake hose from the throttle valve control module (J338).

- Remove throttle valve control module from the intake manifold.

With a Two Piece Intake Manifold

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

Continuation for All

- Disconnect the oxygen sensor connectors - 1 through 4 -.





- Using the (3337), remove the Heated Oxygen Sensor (HO2S) (G39) and HO2S 2 (G108) from the front catalytic converters.

- Remove the exhaust manifold heat shield with intake manifold support.

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

- Raise the vehicle.

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

- Remove the nuts for the flanges.

- Remove the bolts - item 13 -=> [ Bolt ] Description and Operation for the support to the engine/transmission bracket.

- Remove the exhaust pipe to exhaust manifold nuts.

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

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

- Remove the exhaust manifold.

Installing

• When installing the exhaust pipes, ensure that the flange connections after the catalytic converters seal tightly. Leaks in this area produce pulsations in the exhaust. This allows outside air to reach the O2S behind TWC and the oxygen sensor control will be disturbed.

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

The rest of the installation is basically a reverse of the removal sequence.