2.7.5.6 Precautions on Maintenance of Exhaust System 

Warning: Warning on Exhaust Service 

Warning: The broken three-way catalytic converter must be replaced. It is not allowed to 
remove the exhaust system of three-way catalytic converter , otherwise, there will be serious 
air pollution. 

Important precaution : In the following conditions, three-way catalytic converter may be 
damaged or malfunction: 

z  Work exceeds the range of closed-loop mixture control system. 

z  Engine burns a large amount of engine oil. 

z  The three-way catalytic converter exhaust temperature is too high (higher than 840°C). 

 

Precautions: 

z  Vehicles with three-way catalytic converter can not use leaded petrol.  Lead will 

pollute the three-way catalytic converter. 

z  Do not drop the three-way catalytic converter, as this may damage the ceramic carrier. 

z  Do not allow water, engine oil or fuel enter into the converter, because this may 

contaminate the ceramic substrate. 

z  Do not start the vehicle when there is engine misfire or the spark plug wire is 

disconnected. 

523

2.7.6 Removal and installation 

2.7.6.1 Replacement of Exhaust Manifold 

Dismantlement Procedure 

1.  Disconnect the battery negative 

electrode cable. Refer to 2.12.6.1 
Battery Disconnection. 

2.  Dismantle left right fixing nut of 

front air exhaust pipe assembly . 

Note: Dismantling the bolt when it 
is hot is likely to damage the bolt or 
flange nuts weld on the exhaust 
manifold. Dismantle the bolt when 
the engine is cooled down. 

GC02-0210b

3.  Remove the M10×22 bolt from 

the cylinder block and loosen the 
M10 nut to remove the left 
mounting plate of the exhaust 
manifold. 

Note: Dismantling the bolt when it is 
hot is likely to damage the bolt or 
flange nuts weld on the exhaust 
manifold. Dismantle the bolt when 
the engine is cooled down. 

GC03-0087c

4.  Remove the M10×22 bolt from 

the cylinder block and loosen the 
M10 nut to remove the right 
mounting plate of the exhaust 
manifold. 

Note: Dismantling the bolt when it is 
hot is likely to damage the bolt or 
flange nuts weld on the exhaust 
manifold. Dismantle the bolt when 
the engine is cooled down. 

GC02-0088c

524

5.  Remove the four M8×22 bolts 

from the exhaust manifold and 
the exhaust manifold upper heat 
shield. 

Note: Dismantling the bolt when it is 
hot is likely to damage the bolt or 
flange nuts weld on the exhaust 
manifold. Dismantle the bolt when 
the engine is cooled down. 

GC02-0089c

6.  Remove the two M8×22 bolts 

from the exhaust manifold and 
the exhaust manifold lower heat 
shield. 

Note: Dismantling the bolt when it is 
hot is likely to damage the bolt or 
flange nuts weld on the exhaust 
manifold. Dismantle the bolt when 
the engine is cooled down. 

GC02-0089c

7.  Remove the four M8×12 bolts 

from the exhaust manifold and 
the three-way catalytic device 
heat shield. 

Note: Dismantling the bolt when it is 
hot is likely to damage the bolt or 
flange nuts weld on the exhaust 
manifold. Dismantle the bolt when 
the engine is cooled down. 

GC02-0090c

525

8.  Dismantle the exhaust manifold 

bolts and nuts according to the 
sequence in the graph. 

Dismantling the exhaust manifold 
bolts at high temperature may 
damage the bolts or cylinder head. 
Wait until the engine cooling down 
before removal. 

3

1

4

5

2

GC02-0091c

9.  Dismantle the exhaust manifold. 

10. Remove the exhaust manifold 

gasket from the double end stud 
of the cylinder head. 

GC02-0092c

Installation Procedure: 

1.  Install the exhaust pipe to engine 

bracket bolts. 

Torque: 35-45 N . m(Metric) . 25. 
8-33 . 2 lb-ft(English system) 

GC02-0210b

526