Removal

Removal

1. Raise vehicle on ramp.
2. Remove rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve Assembly - Remove for Access & Refit).
3. Disconnect multiplugs (x2), HEGO sensors.
4. Release sensor lead from clip on heatshield.
5. Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes.
6. Loosen LH and RH clamp nuts, catalysts to centre pipe.
7. With assistance, manoeuvre exhaust centre pipe assembly rearwards to release from catalysts.
8. Remove nuts (x3), catalyst to exhaust manifold.
9. With assistance, release and support weight of RH catalyst from exhaust manifold.
10. Manoeuvre HEGO sensor leads and remove cable tie. Release HEGO sensor leads from behind heat shield. Remove string from HEGO multiplugs.
11. Remove catalyst assembly.
12. Remove and discard gasket.
13. Remove HEGO sensors (x2) from catalyst.

Installation

1. Clean catalyst, mating joint faces and HEGO sensors..
2. Install and tighten HEGO sensors (x2) to catalyst.
3. Apply proprietary exhaust sealant around pipe joints.
4. Install new gasket to exhaust manifold flange.
5. With assistance, position catalyst, secure string (x2) to HEGO multiplugs, feed sensor leads behind heat shield. Secue cable tie. Install catalyst to exhaust manifold.
6. Install and torque tighten nuts (x3), catalyst to exhaust manifold.
7. Align centre pipe asembly to catalyst, torque tighten clamp nuts.
8. Remove string (x2), connect multiplugs (x2), HEGO sensors.
9. Secure sensor lead in clip on heatshield.
10. Install rear exhaust silencer (refer to Workshop Manual procedure 09.00.KA Muffler & Bypass Valve Assembly - Remove for Access & Refit).
11. Lower vehicle on ramp.

LH Exhaust Manifold-Renew-Roadster Only

Removal

1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield - Front Floor - Renew).
4. Remove LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH - Renew).
5. Remove nuts (x8), securing manifold to cylinder head.
6. Remove exhaust manifold, remove and discard gasket.

Installation

1. Clean manifold and mating face on engine. Install new gasket to engine.
2. Install manfold to engine.
3. Install nuts (x8) securing manifold to cylinder head (torque).
4. Install LH front wheel arch liner (refer to Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front - LH - Renew).
5. Install heatshield deflector, front floor (refer to Workshop Manual procedure 09.04.AA Heatshield - Front Floor - Renew).
6. Lower vehicle on ramp.
7. Connect vehicle battery.

Heated Exhaust Gas Oxygen (HEGO) Sensor - Remove and Install

Removal

1. Raise the vehicle and make it safe.
2. Release the two electrical connnectors for the Heated Exhaust Gas Oxygen (HEGO) sensor from the bracket.
3. Disconnect the two electrical connnectors from the HEGO sensor.
4. Move the two wiring harnesses for the HEGO sensor away.
5. Remove the two bolts that attach the bracket to the engine.
6. Remove the bracket.
7. Remove the two bolts that attach the heat shield to the torque tube.
8. Move the heat shield away.

WARNING
THE EXHAUST SYSTEM WILL BE VERY HOT AFTER OPERATION. LET THE EXHAUST COOL BEFORE YOU DO WORK. IF YOU DO NOT, PESONAL INJURY CAN OCCUR.