Catalytic Converter: Service and Repair

EXHAUST MANIFOLD AND THREE WAY CATALYST

EXHAUST MANIFOLD AND THREE WAY CATALYST:

REMOVAL
1. Remove engine cover with power tool.
2. Remove air cleaner case and air duct.
3. Remove undercover with power tool.





4. Remove exhaust front tube and three way catalyst.
5. Using heated oxygen sensor wrench (special service tool), remove heated oxygen sensors.

CAUTION: Be careful not to damage heated oxygen sensor.

6. Remove exhaust manifold cover.








7. Loosen nuts in the reverse order of illustration to remove exhaust manifold with power tool.

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







INSPECTION AFTER REMOVAL / Surface Distortion
Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface.

Limit:.....................0.3 mm (0.012 inch)

INSTALLATION
Install in the reverse order of removal paying attention to the following.







Installation of Exhaust Manifold Gasket
Install in direction shown below. (Follow same procedure for both banks.)

Locate thick side of port connecting part on right side from operator's view.

Locate round press in thick side of port connecting part above center level line of port.




Installation of Exhaust Manifold
If stud bolts were removed, install them and tighten to the torque specified below.
12.7 - 16.7 Nm (1.3 - 1.7 kgf-cm, 10 - 12 ft. lbs.)

Exhaust Manifold Bolt Sequence - Right:

Exhaust Manifold Bolt Sequence - Left:

Install exhaust manifold in the numerical order as shown in the figure.

Tighten nuts No.1 and No.2 in two steps. Order No. 7 and No. 8 shows second step.



Installation of Heated Oxygen Sensor

CAUTION: When using heated oxygen sensor wrench (KV10114400), tighten to the middle of specified torque because length of tool may induce slight indication increase. (Do not tighten to the maximum specified torque)

Before installing a new heated oxygen sensor, clean exhaust system threads using oxygen sensor thread clearer fool, J-43897-18 or J-43897-12, and apply anti-seize lubricant.

Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MIL coming on.