Catalytic Converter: Service and Repair

EXHAUST MANIFOLD AND THREE WAY CATALYST

EXHAUST MANIFOLD AND THREE WAY CATALYST:

REMOVAL
1. Remove the engine undercover.
2. Disconnect the electrical connector of each heated oxygen sensor, and unhook the harness from the bracket and middle clams on the cover.







3. Remove the heated oxygen sensors with 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; use a new one.

4. Remove the lower exhaust manifold covers.
5. Remove the exhaust front tube.
6. Remove the upper exhaust manifold cover.







7. Loosen the nuts in the sequence shown, on the exhaust manifold and three way catalyst.
8. Remove the exhaust manifold and three way catalyst assembly and gasket. Discard the gasket.


INSPECTION AFTER REMOVAL
Surface Distortion







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


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


INSTALLATION
Installation is in the reverse order of removal. Pay attention to the following.

Exhaust Manifold Sequence:

Tighten the nuts in the numerical order shown, to specification. After tightening No.5, retighten No.1 and then No.3 to specification.


Installation of Heated Oxygen Sensors
lean the heated oxygen sensor threads with the Tool, then apply the anti-seize lubricant to the threads before installing the heated oxygen sensors.

CAUTION: Do not over-tighten the heated oxygen sensors. Doing so may cause damage to the heated oxygen sensors, resulting in a malfunction and the MIL coming on.