Catalytic Converter: Service and Repair

EXHAUST MANIFOLD AND THREE WAY CATALYST


Removal and Installation












REMOVAL
1. Remove the engine under cover. Service and Repair.
2. Remove the splash shield (RH). Component.
3. Remove generator and generator bracket. Service and Repair.
4. Remove the exhaust front tube. Component.
5. Remove oil level indicator tube.
6. Disconnect the electrical connector of heated oxygen sensor 1 or air fuel ratio (A/F) sensor 1, and unhook the harness from the bracket and middle clamp on the cover.





7. Remove the heated oxygen sensor 1 or air fuel ratio (A/F) sensor 1 using Tool.





CAUTION:
- Be careful not to damage heated oxygen sensor or air fuel ratio (A/F) sensor.
- Discard any heated oxygen sensor or 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; use a new one.
8. Remove the lower exhaust manifold covers.
9. Remove the upper exhaust manifold cover.





10. Loosen the nuts in reverse order as shown, on the exhaust manifold and three way catalyst.
11. Remove the exhaust manifold and three way catalyst assembly and gasket. Discard the gasket.

INSPECTION AFTER REMOVAL
Surface Distortion





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

Limit : 0.7 mm (0.0276 in)

INSTALLATION
Installation is in the reverse order of removal. Pay attention to the following.





Tightening Exhaust Manifold Nuts
- Tighten the nuts in the numerical order shown, to specification.
Installation of A/F Sensors and Heated Oxygen Sensors
Clean the A/F sensor and heated oxygen sensor threads with the Tool, then apply the anti-seize lubricant to the threads before installing the A/F sensor and heated oxygen sensors.





CAUTION:
Do not over-tighten the A/F sensors and heated oxygen sensors. Doing so may cause damage to the
A/F sensors and heated oxygen sensors, resulting in a malfunction and the MIL coming on.