Exhaust Manifold and Three Way Catalyst

EXHAUST MANIFOLD AND THREE WAY CATALYST





Removal and Installation
REMOVAL

WARNING: Perform the work when the exhaust and cooling system have completely cooled down.

1. Remove engine cover with power tool.
2. Drain engine coolant.

CAUTION:
^ Perform this step when the engine is cold.
^ Do not spill engine coolant on drive belts.

3. Remove air cleaner case and air duct.
4. Remove front and rear engine undercover and front cross bar with power tool.
5. Disconnect heated oxygen sensors 2 (bank 1 and bank 2) harness connectors.





6. Using the heated oxygen sensor wrench (SST), remove heated oxygen sensors 2 (bank 1 and bank 2).

CAUTION:
^ Be careful not to damage heated oxygen sensor.
^ Discard any heated oxygen sensor which has been dropped onto a hard surface such as a concrete floor; replace with a new sensor.

7. Remove exhaust mounting bracket between three way catalysts (right and left bank) and transmission.
8. Remove three way catalysts (right and left bank).
9. Disconnect air fuel ratio sensor 1 (bank 1 and bank 2) harness connectors and remove harness clip.





10. Using the heated oxygen sensor wrench (SST), remove air fuel ratio sensor 1 (bank 1 and bank 2).

CAUTION:
^ Be careful not to damage air fuel ratio sensor.
^ Discard any air fuel ratio sensor which has been dropped onto a hard surface such as a concrete floor; replace with anew sensor.

11. Remove water pipe and heater pipe on both right and left side.
12. Remove exhaust manifold cover (right and left bank).





13. Loosen mounting nuts in the reverse order as shown in the figure to remove exhaust manifold with power tool.

NOTE: Disregard the numerical order No. 7 and 8 in removal.

INSPECTION AFTER REMOVAL
Surface Distortion





^ Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge.
Limit: 0.3 mm (0.012 inch)
^ If it exceeds the limit, replace exhaust manifold.

INSTALLATION
Note the following, and install in the reverse order of removal.

Exhaust Manifold Gasket





^ Install in direction shown below. (Follow same procedure for both banks.)
^ Locate thick side of port connecting part on right side from technician's view.
^ Locate round press in thick side of port connecting part above center level line of port.

Exhaust Manifold
^ If stud bolts were removed, install them and tighten to the specified torque below.
Torque: 14.7 Nm (1.5 kg-m, 11 ft. lbs.)





^ Install exhaust manifold and tighten mounting bolts in numerical order as shown in the figure.

NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 shows second step.

Air Fuel Ratio Sensor and Heated Oxygen Sensor

CAUTION:
^ Before installing a new air fuel ratio sensor and new heated oxygen sensor, clean exhaust system threads using heated oxygen sensor thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize lubricant.
^ Do not over torque air fuel ratio sensor and heated oxygen sensor. Doing so may cause damage to air fuel ratio sensor and heated oxygen sensor, resulting in the MIL coming on.