Exhaust Manifold and Three Way Catalyst: Removal and Installation

Exhaust Manifold and Three Way Catalyst: Removal and Installation [VQ4ODE]

REMOVAL (LH)

WARNING:
Perform the work when the exhaust and cooling system have cooled sufficiently.

1) Remove air cleaner case and air duct and resonator assembly.
2) Remove the air dam using power tool.
3) Remove engine undercover using power tool.
4) Disconnect harness connector and remove LH and RH heated oxygen sensor 2 using Tool.





Tool number: KV10114400 (J-38365)

CAUTION:
^ Be careful not to damage heated oxygen sensor 2.
^ Discard any heated oxygen sensor 2 which has been dropped from a height of more than 0.5 m (19.70 in) onto a hard surface such as a concrete floor; replace with a new sensor.

5) Remove center exhaust tube, main muffler and left front exhaust tube.
6) Remove exhaust manifold cover (LH).
7) Disconnect harness connector and remove air fuel ratio sensor 1 (LH) using Tool (A).





^ White Arrow Indicates Front
Tool number: KV991J0050 (J44626)

CAUTION:
^ Be careful not to damage air fuel ratio sensor 1.
^ Discard any air fuel ratio sensor 1 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.

8) Remove three way catalyst (LH).
9) Loosen nuts with power tool in reverse order as shown.





^ White Arrow Indicates Front

NOTE:
Disregard the numerical order No. 7 and 8 in removal.
10) Remove gaskets.

CAUTION:
Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL

Surface Distortion
^ Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge.





Limit: 0.3 mm (0.012 in)
^ If it exceeds the limit, replace exhaust manifold.

INSTALLATION (LH)
Installation is in the reverse order of removal.

Exhaust Manifold Gasket
Install the exhaust manifold gasket in direction as shown.





^ White Arrow Indicates Front
^ A: Identification hole

Exhaust Manifold
^ If stud bolts were removed, install them and tighten to the specified torque.
Exhaust manifold stud torque: 14.7 Nm (1.5 kg-m, 11 ft-lb)
^ Install exhaust manifold and tighten nuts in numerical order as shown.





CAUTION:
Use new exhaust manifold nuts for installation.

NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 show second step.

- White Arrow Indicates Front

Heated Oxygen Sensor

CAUTION:
^ Do not over tighten air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the "MIL" coming on.
^ Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system threads using oxygen sensor thread cleaner and apply anti-seize lubricant.

Tool number
: - (J-43897-12)
: - (J-43897 18)

REMOVAL (RH)
1) Remove engine assembly.
2) Loosen nuts with power tool in reverse order as shown.





^ White Arrow Indicates Front

NOTE:
Disregard the numerical order No. 7 and 8 in removal.

3) Remove gaskets.

CAUTION:
Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL

Surface Distortion
^ Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge.





Limit: 0.3 mm (0.012 in)
^ If it exceeds the limit, replace exhaust manifold.

INSTALLATION (RH)
Installation is in the reverse order of removal.

Exhaust Manifold Gasket
Install the exhaust manifold gaskets in direction as shown.





^ White Arrow Indicates Front
^ A: Identification hole

Exhaust Manifold
^ If stud bolts were removed, install them and tighten to the specified torque.
Exhaust manifold stud torque: 14.7 Nm (1.5 kg-m, 11 ft-lb)
^ Install exhaust manifold and tighten nuts in numerical order as shown.





CAUTION:
Use new exhaust manifold nuts for installation.

NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 show second step.

^ White Arrow Indicates Front

Heated Oxygen Sensor

CAUTION:
^ Do not over tighten air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the "MIL" coming on.
^ Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system threads using oxygen sensor thread cleaner and apply anti-seize lubricant.

Tool number
: - (J-43897-12)
: - (J-43897-18)