Removal and Installation

EXHAUST MANIFOLD AND THREE WAY CATALYST


Removal and Installation


REMOVAL

WARNING:
Perform the work when the exhaust and cooling system have cooled sufficiently.
1. Remove the engine undercover (rear) using power tool (4WD models).
2. Remove front final drive assembly (4WD models). .
3. Remove the main muffler assembly and center exhaust tube. Removal and Installation.
4. Remove the front exhaust tubes. Removal and Installation.
5. Remove front tires. Rotation.
6. Remove fender protectors. Service and Repair.
7. Remove the LH and RH air fuel ratio A/F sensors.
- Follow steps below to remove each air fuel ratio A/F sensor.
a. Remove the harness connector of each air fuel ratio A/F sensor, and harness from bracket and middle clamp.





b. Remove the air fuel ratio A/F sensors from both LH and RH exhaust manifolds using Tool.

Tool number : - (J-44626)


CAUTION:
- Do not damage the air fuel ratio A/F sensors
- Discard any air fuel ratio A/F sensor which has been dropped from a height of more than 0.5m (19.7 in) onto a hard surface such as a concrete floor. Replace it with a new one.
8. Support the engine using a suitable tool.





9. Remove the exhaust manifold (LH) (A) following the steps below.
- : Front
- B: Exhaust manifold (RH)
a. Remove the engine mounting insulator. Exploded View.
b. Remove the exhaust manifold cover.
c. Remove the engine mounting bracket. Exploded View.
d. Loosen the nuts in reverse order as shown using power tool.
e. Remove the exhaust manifold (LH) (A).





10. Remove the exhaust manifold (RH) (B) following the steps below.
- : Front
- A: Exhaust manifold (LH)
a. Remove the engine mounting insulator. Exploded View.
b. Remove the exhaust manifold cover.
c. Remove the engine mounting bracket. Exploded View.
d. Remove the oil level gauge guide. Exploded View Removal and Installation, "Exploded
View".
e. Loosen the nuts in reverse order as shown using power tool.
f. Remove the exhaust manifold (RH) (B).

INSPECTION AFTER REMOVAL

Surface Distortion





- Check the flatness of each exhaust manifold flange surface using suitable tools.

Flatness limit : 0.3 mm (0.012 in)

- If measurement exceeds the limit, replace the exhaust manifold.

INSTALLATION
Installation is in the reverse order of removal.





- Install new exhaust manifold gasket with the top of the triangular up mark on it facing up and its coated face (gray side) toward the exhaust manifold side.





- Tighten the exhaust manifold nuts LH and RH in the numerical order shown. Then recheck the torque of the nuts.
- A: Exhaust manifold (LH)
- B: Exhaust manifold (RH)
- : Front
- Before installing new air fuel ration A/F sensors, clean the exhaust system threads using suitable tool and apply anti-seize lubricant.

Oxygen sensor thread cleaner : (J-43879-12)
Oxygen sensor thread cleaner : (J-43897-18)


CAUTION:
- Do not over tighten the air fuel ratio A/F sensors. Doing so may cause damage to the sensor, resulting in the MIL coming on.