Removal and installation the exhaust manifold with the catalytic converter assembly
Note: The exhaust manifold is integrated with the catalytic converter, so the exhaust manifold can only be removed as an assembly with the catalytic converter.
Attention:
- The catalytic converter contains ceramic fibers placed in a closed block. Drilling or cutting the catalytic converter is prohibited.
- Use glasses with side protection and cut-resistant gloves for work.
Removal the exhaust manifold with the catalytic converter assembly
1. Place the vehicle on a two-post lift.
2. Disconnect the negative battery terminal.
3. Remove the air intake duct.
4. Loosen the mounting bolts and remove the engine protective pan.
5. Remove the oxygen sensors.
6. Loosen the bolts (1) and remove the catalytic converter heat shield.
7. Unscrew the nuts (2) of the exhaust pipe on the catalytic converter.
8. Unscrew the nuts securing the exhaust manifold with the catalytic converter assembly to the cylinder head.
9. Loosen the nuts (3) of the catalytic converter bracket
10. Remove the catalytic converter bracket (4).
11. Remove the exhaust manifold with the catalytic converter assembly.
12. Remove the exhaust manifold gasket.
Installing the exhaust manifold with catalytic converter assembly
Caution: To ensure proper sealing, contact surfaces must be clean, dry and free of grease (keep fingerprints away).
1. Using fine-grained sandpaper, clean the contact surfaces of the cylinder head and exhaust manifold (if reused), expansion chamber, catalytic converter (if reused).
2. Using a cleaning agent and a clean cloth, clean and degrease the contact surfaces of the cylinder head and exhaust manifold (if reused), expansion chamber, catalytic converter (if reused).
Note:
- If the threaded studs were loose during removal, apply a high-strength locking compound to their threads and tighten to a torque of 9 Nm.
- Tightening torque of exhaust pipe threaded studs: 7 Nm.
Caution: To avoid overheating of surrounding components, be careful not to damage the heat shields (do not tear, bend, stretch, etc.). If the heat shield is damaged in any way, it must be replaced with a new one.
3. Install a new exhaust manifold gasket.
Caution: Be sure to replace the exhaust manifold gasket with a new one.
4. Install the exhaust manifold with the catalytic converter assembly.
5. Tighten the exhaust manifold and catalytic converter assembly mounting nuts in the sequence shown in the figure to a torque of 25 N·m.
6. Install a new exhaust pipe sealing ring.
7. Tighten the exhaust pipe and catalytic converter bracket nuts to 21 N·m.
8. Install the heat shield.
9. Tighten the catalytic converter heat shield bolts to 12 Nm.
10. Ensure that all exhaust pipe heat shields are in place and installed correctly.
11. Check for contact between the exhaust pipe and the underbody.
12. Check the tightness of the exhaust pipe.
13. Install oxygen sensors.
14. Install the engine protective pan.
15. Remove the air intake duct.
16. Connect the negative battery terminal.