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.

1. Remove the front wheel and tires using power tool.
2. Remove the engine undercover.
3. Remove the inner wheel well splash shields.
4. Remove the radiator and cooling fan assembly. Refer to "Removal and Installation".
5. Remove the front exhaust tube. Refer to "Removal and Installation".
6. Remove the front suspension member. Refer to "Removal and Installation".





7. Remove the RH and LH three way catalyst support bolts in the order as shown.
8. Remove heated oxygen sensor 2 (bank 1), heated oxygen sensor 2 (bank 2), air fuel ratio (A/F) sensor 1 (bank 1) and air fuel ratio (A/F) sensor 1 (bank 2).
a. Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp.
b. Remove both heated oxygen sensors and air fuel ratio (A/F) sensors using Tool.
Tool numbers : KV10114400 (J-38365) : KV10117100 (J-3647-A)

CAUTION:
^ Be careful not to damage heated oxygen sensors or air fuel ratio (A/F) sensors.
^ 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.

9. Remove exhaust manifold and three way catalyst heat shields with power tool.
10. 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.








11. Remove the exhaust manifolds. Loosen the exhaust manifold nuts in the order as shown.

INSPECTION AFTER REMOVAL
Surface Distortion





^ Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces.
Limit : 0.15 mm (0.006 inch)

INSTALLATION





Installation is in the reverse order of removal.
^ Install the exhaust manifold nuts in the order as shown.
Exhaust manifold nuts: 28.4 - 33.3 Nm (2.9 - 3.3 kg-m, 21 - 24 ft. lbs.)

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.

Tool numbers : KV10114400 (J-38365) : KV10117100 (J-36471-A)

^ Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust manifold threads using the oxygen sensor thread cleaner tool, and apply anti-seize lubricant.

Tool numbers : J-43897-18 : J-43897-12





^ Do not overtighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause damage.





^ Install the RH and LH three way catalyst support bolts in the order as shown.
Three way catalyst support bolts : 19 - 25 Nm (2.0 - 2.5 kg-m, 14 - 18 ft. lbs.)





^ Install the exhaust manifold heat shield bolts.
Exhaust manifold heat shield bolts : 5.1 - 6.5 Nm (0.52 - 0.66 kg-m, 46 - 57 inch lbs.)

^ Install the three way catalyst heat shield bolts.
Three way catalyst heat shield bolts : 6.7 - 9.8 Nm (0.69 - 0.99 kg-m, 60 - 86 inch lbs.)