Catalytic Converter: Service and Repair

EXHAUST MANIFOLD AND THREE WAY CATALYST





Removal and Installation

REMOVAL

WARNING:
^ Perform the work when the exhaust and cooling system have completely cooled down.
^ When removing the front and rear engine mounting through bolts and nuts, lift the engine up slightly for safety. For engine slingers, refer to step 17 in "REMOVAL".

1. Remove the front wheel and tires with power tool.
2. Remove the engine undercovers with power tool.
3. Remove the inner wheel well splash shields with power tool.
4. Remove the radiator and cooling fan assembly.
5. Remove the front exhaust tube.





6. Remove the front suspension member as follows:





CAUTION: Before disconnecting, support the front suspension member with a suitable power lift. Use the lift to lower the member to remove it.

a. Disconnect the lower ball joints.
b. Remove the steering gear mounting bolts.
c. Disconnect the upper sway bar connecting rod.
d. Disconnect the front and rear engine mounts electrical connectors, if equipped. Remove the front and rear engine mount through bolts and nuts using power tool.

CAUTION: For vehicles equipped with an automatic transaxle, the front and rear engine mounts are electrically controlled. Disconnect the engine mount electrical connector(s) before removing the through bolt and nut.

e. Disconnect the power steering line bracket.
f. Remove the LH and RH drive axles.
g. Remove the front suspension member mounting nuts and lower the member out of the engine compartment.
7. Remove heated oxygen sensor 1 (front) (bank 1) and heated oxygen sensor 2 (front) (bank 2).
a. Remove harness connector of each heated oxygen sensor, and disconnect the harness from the bracket and middle clamp.
b. Remove both heated oxygen sensors with the Tool.

CAUTION:
^ Be careful not to damage heated oxygen sensor.
^ Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 inch) onto a hard surface such as a concrete floor; replace with a new sensor.

8. Remove exhaust manifolds and the three way catalyst heat shields with power tool.
9. Remove the three way catalyst (manifold) (bank 1) and three way catalyst (manifold) (bank 2) by loosening the bolts first and then removing the nuts and through bolts.





10. Remove the exhaust manifolds. Loosen the nuts in the numerical order as shown.

INSPECTION AFTER REMOVAL
Surface Distortion
^ Use a reliable gauge to check the flatness of the exhaust manifold mating surfaces.
Distortion limit: 0.3 mm (0.012 inch)

INSTALLATION





^ Installation is in the reverse order of removal.
^ Install the exhaust manifold nuts in the numerical order as shown.

CAUTION: When using the heated oxygen sensor wrench, tighten to the middle of specified torque range, because the length of the Tool may increase the actual tightness. Do not tighten to the maximum specified torque range.
^ Before installing a heated oxygen sensor, clean the exhaust manifold threads using the oxygen sensor thread cleaner tool, and apply anti-seize lubricant.
^ Do not over-torque the heated oxygen sensors. Doing so may cause damage to the heated oxygen sensors.