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, Removal and Replacement.
1. Remove engine and CVT assembly. Removal and Replacement.
2. Remove the RH and LH three way catalyst support brackets.
3. 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.





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 in) onto a hard surface such as a concrete floor; replace with a new sensor.
4. Remove exhaust manifold and three way catalyst heat shields with power tool.
5. 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.









6. Remove the exhaust manifolds RH (A) and LH (B). Loosen the exhaust manifold nuts in the order as shown.

Arrow Indicates : Front

INSPECTION AFTER REMOVAL

Surface Distortion





- Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces.

Limit : 0.3 mm (0.012 in)

INSTALLATION
Installation is in the reverse order of removal.









- Install the exhaust manifold nuts in the order as shown RH (A) and LH (B).

Arrow Indicates : Front

- Install RH (A) and LH (B) three way catalyst support brackets.





- Hand tighten the three way catalyst support bracket bolts to seat the support brackets.
- Tighten the bolts to specification in the numerical order as shown.

CAUTION:
Do not tighten if support brackets do not fit tightly against oil pan and three way catalysts.

Three way catalyst support bracket bolts : 22.0 N.m (2.2 kg-m, 16 ft-lb)

CAUTION:
- 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.





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