Removal And Installation

EXHAUST MANIFOLD AND THREE WAY CATALYST

Removal and Installation


REMOVAL

1.Remove the engine under cover. Refer to "Removal and Installation" Removal And Installation.
2.Remove the exhaust front tube. Refer to "Exploded View" Exploded View.
3.Remove the front air duct and air cleaner assembly. Refer to "Removal and Installation" Removal And Installation.
4.Disconnect the air fuel ratio (A/F) sensor 1 electrical harness connector.
5.Remove the exhaust manifold cover (upper).





6.Remove the air fuel ratio (A/F) sensor 1 (1) using Tools (A), (if necessary).

Tool numbers : KV991J0050 (J-44626)
: KV10117100 (J-36471-A)

CAUTION:
- Be careful not to damage air fuel ratio (A/F) sensor.
- Discard any air fuel ratio (A/F) 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 one.
7.Remove the oil level gauge and oil level gauge guide. Refer to "Exploded View" Exploded View.
8.Remove the exhaust manifold cover (lower front).





9.Loosen the exhaust manifold and three way catalyst nuts in the reverse order as shown.

White arrow indicates : Engine front

10.Remove the exhaust manifold and three way catalyst assembly and gasket. Discard the gasket.
11.Remove the exhaust manifold cover (lower rear).

INSPECTION AFTER REMOVAL

Surface Distortion





- Use a reliable straightedge (A) and feeler gauge (B) to check the flatness of exhaust manifold mating surface.
NOTE:
Place the straightedge (A) diagonally and measure in several locations.

Limit: 0.3 mm (0.012 in)

INSTALLATION

Exhaust Manifold
1.Install studs in cylinder head and exhaust manifold (if removed). Then tighten to specification.

CAUTION:
Do not reuse cylinder head or exhaust manifold studs.





2.Install exhaust manifold cover (lower rear) (if removed) and bolts. Then tighten the bolts to specification in the numerical order shown.

CAUTION:
Do not reuse bolts.





3.Install the exhaust manifold and gasket. Then tighten the nuts to specification in the numerical order shown.

CAUTION:
Do not reuse gasket.

White arrow indicates : Engine front





4.Install the exhaust manifold cover (lower front) and bolts. Then tighten the bolts to specification in the numerical order shown.

CAUTION:
Do not reuse bolts.





5.Install the air fuel ratio (A/F) sensor 1 (1) using Tools (A) and tighten to specification.

Tool numbers : KV991J0050 (J-44626)
: KV10117100 (J-36471-A)

CAUTION:
- Be careful not to damage air fuel ratio (A/F) sensor.
- Discard any air fuel ratio (A/F) 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 one.
- Do not over-tighten the air fuel ratio (A/F) sensor 1. Doing so may cause damage to the air fuel ratio (A/F) sensor 1, resulting in a malfunction and the MIL coming on.





6.Install the exhaust manifold cover (upper). Then tighten the bolts to specification in the numerical order shown.

CAUTION:
Do not reuse bolts.
7.Installation of the remaining components is in the reverse order of removal.