Catalytic Converter: Service and Repair

EXHAUST MANIFOLD AND THREE WAY CATALYST

EXHAUST MANIFOLD AND THREE WAY CATALYST:

REMOVAL
1. Remove strut tower bar.
2. Remove engine cover with power tool. Refer to Intake Manifold Collector.
Service and Repair

3. Remove air cleaner case and air duct.
4. Remove undercover with power tool.







5. Using heated oxygen sensor wrench (special service tool), remove rear heated oxygen sensors.

CAUTION: Be careful not to damage heated oxygen sensor.







6. Remove bracket between right/left catalytic converter and transmission.
7. Remove three way catalyst.
8. Using heated oxygen sensor wrench (special service tool), remove front heated oxygen sensors.


CAUTION: Be careful not to damage heated oxygen sensor.

9. Remove water pipes on both RH and LH side.
10. Remove exhaust manifold cover.










11. Loosen nuts in the reverse order of illustration to remove exhaust manifold with power tool.

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



INSPECTION AFTER REMOVAL
Surface Distortion







Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface.

Limit:..................0.3 mm (0.012 inch)

EXHAUST MANIFOLD AND THREE WAY CATALYST:

INSTALLATION
Install in the reverse order of removal paying attention to the following.

Exhaust Manifold Gasket:

Installation of Exhaust Manifold Gasket
Install in direction shown. (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.











Installation of Exhaust Manifold
If stud bolts were removed, install them and tighten to the torque specified.

12.7 - 16.7 Nm (1.3 - 1.7 kgf-cm, 10 - 12 ft. lbs.)

Install exhaust manifold in the numerical order as shown in the figure.

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



Installation of Heated Oxygen Sensor

CAUTION: When using heated oxygen sensor wrench (KV10114400), tighten to the middle of specified torque because length of tool may induce slight indication increase. Do not tighten to the maximum spec if fed torque.

Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen sensor thread cleaner tool, J-43897-18 or J-43897-12, and apply anti-seize lubricant.

Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MIL coming on.