Removal and Installation

EXHAUST MANIFOLD AND THREE WAY CATALYST

Removal and Installation


REMOVAL


WARNING:
Perform the work when the exhaust and cooling system have cooled sufficiently.
1.Drain engine coolant from radiator. Refer to "Draining" Draining Engine Coolant.

CAUTION:
- Perform this step when the engine is cold.
- Never spill engine coolant on drive belt.
2.Remove reservoir tank. Refer to "Exploded View" Exploded View.
3.Remove drive belt. Refer to "Removal and Installation" Removal and Installation.
4.Remove power steering oil pump. Refer to "Exploded View" Exploded View.
5.Remove radiator. Refer to "Exploded View" Exploded View.
6.Remove front under cover. Refer to "Exploded View" Exploded View.
7.Remove front wheels and tires. Refer to "Exploded View" Exploded View.
8.Remove A/C compressor. Refer to "Exploded View" Exploded View.
9.Remove alternator and alternator bracket. Refer to "Exploded View" Exploded View.
10.Remove exhaust front tube (bank 1 and bank 2). Refer to "Exploded View" Exploded View.
11.Remove front propeller shaft. Refer to "Exploded View" Exploded View.
12.Disconnect steering lower joint. Refer to "Exploded View" Exploded View.
13.Remove air fuel ratio sensor 1 as per the following:

CAUTION:
Air fuel ratio sensor 1 is not reusable. Never remove air fuel ratio sensor 1 unless this is required.





- Using the heated oxygen sensor wrench [SST: KV10117100
(J-44626)] (A), remove air fuel ratio sensor 1 (1).





14.Remove exhaust manifold cover.
15.Remove oil level gauge guide. Refer to "Exploded View" Exploded View.
16.Remove exhaust manifold.





- Loosen nuts in the reverse order of figure to remove exhaust manifold with a power tool.





17.Remove exhaust manifold gaskets.

CAUTION:
Cover engine openings to avoid entry of foreign materials.

INSTALLATION

Note the following item, and install in the reverse order of removal.
Exhaust Manifold Gasket





- Install exhaust manifold gasket in directional shown in the figure.





NOTE:
When install exhaust manifold gasket, coating surface (black) shall be located on the exhaust manifold side.
Exhaust Manifold





- Tighten mounting nuts in numerical order as shown in the figure.






CAUTION:
All exhaust manifold nuts are tightened at twice.
Air Fuel Ratio Sensor 1

CAUTION:
- Before installing a new air fuel ratio sensor 1, clean exhaust system threads using oxygen sensor thread cleaner (commercial service tool: J-43897-18 or J-43897-12), and apply anti-seize lubricant (commercial service tool).
- Air fuel ratio sensor 1 is not reusable. Replace them with a new one after removal. When replacing them, handle with care not to impact on them.





- When installing the new air fuel ratio sensors 1 (1), set the heated oxygen sensor wrench [SST: KV10117100(J-44626)] (A) in the hexagonal part to tighten the them.
- Never over torque sensors. Doing so may cause damage to the sensors, resulting in "MIL" coming on.
- Prevent rust preventives from adhering to the sensor body.